? 1.9TD block w/ 1.6TD heads ?

[mstephenson]

Hello Everyone,

I hope I didn't mess up. I went and looked at a car I didn't need or particularly want. And yes, I bought it. A MK2 Golf. The ad said 1.9 tdi. I didn't know what I was looking at since the only engine/s I studied was/were MK1 1.5na and 1.6na.

So, the son said the father (deceased 2001) ordered the block from California from a Passat. He said it was an ALH block. It looks like some kind of similar conversion of what is being sold on eBay (http://www.ebay.com/itm/VW-Volkswagen-1-9D-LONG-BLOCK-ENGINE-with-1-5-1-6-to-1-9-UPGRADE-KIT-/171529128211). Eventually, I was told it was a 1.9 block (confirmed the block stamp is really a 1.9D not TD) with the original 1.6TD head and components bolted on including some modifications. Assuming this is true, then I have questions:

--What is this block? Block stamp 1.9D below exhaust and this is the number from below #3 and #4 (20J93). If this is enough to ID, is there a database to resource?







—Motor observations. The block should have <40Kmiles on it while the head and other transferables will have something around 125Kmiles. The motor seems tight after 3000rpm. The turbo is barely audible. No obvious whistling or spooling sound, but it’s there for sure. Sweet spot is 3000rpm (~65mph) in 4th. Does that sound about right?

--Is this setup ok? and reliable? I want to drive 90 miles a day, every day; nothing fancy; good mpg (+40), and not get run over.

--Oil capacity. What should I know? It has an oil cooler. Does it need a deeper pan if it is the original 1.6 pan? Frankly, I have no idea if this matters. I read 4.5l (4.8Q) for 1.9TDI?

--Injection pump. What is this? 1.6 or 1.9 pump? and does it matter? The son said the father took it to a diesel shop (not a VW shop) to do something about it starving fuel to motor.



—Turbo. How/Where to ID the turbo?

--Transmission. The numbers were scratched off. Does this matter? Also, the speedo cable looks like this on the tranny end and the other end is some kind of sensor sensing a magnet epoxied to the axle. Do I need to put a legit cable back in?



The water temp gauge hardly moves. I plan on putting a mechanical gauge shortly. That terrifies me.

What are some observable differences between the 1.6D and 1.9D. Can you recommend some specific items I need to read up on to be a responsible TD owner/operator?

That's all I can think of at this moment. I am sure I am not done questioning the purchase or my sanity. Thank you everyone.


Michele

[libbydiesel]

None of your pics show the block code.  The block code is not part of the casting.  It is stamped INTO the machined surface shown here: 

It is not a TDI.  It is definitely NOT an ALH block.  It is probably a 1Y.

The head is *not* a 1.6 head.  It is a 1.9 head.

Best way to identify what turbo it has is to take a picture of it and post it up here.

It should be reliable engine if maintained well. 

[vanbcguy]

Looks like an AAZ to me - block code will tell for sure. Appears to be a reasonably well done installation too, nothing sticks out at me as being really off. The intake appears to be a factory AAZ piece, that's definitely a 1.9 IDI head, etc. My guess is its a totally complete AAZ, which is an IDI turbo diesel.

They're fine engines - looks like it has been set up to use the v-belt accessories from the 1.6 which is good, that actually solves one of the weaknesses of the 1.9 engines in their stock form (they had an issue with the crank nose caused by the switch to a serpentine belt and a heavier more powerful alternator).

Oil volume will be the same as for a 1.6. The engines are extremely similar. Use a good quality diesel rated xW40 oil - if it isn't leaking or burning it then a synthetic like Rotella T6 5w40 would be a great choice. If it's using oil then Rotella T 15w40 (the non synthetic cheaper one) will be fine.

Injection pump appears correct for an IDI diesel. Looks to be in good shape too.

I think you did well!

Bryn

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[libbydiesel]

My guess is 1Y as opposed to AAZ because he mentioned the block says 1.9D instead of 1.9TD on the back of it.  I'll be curious to find out the block code.

[mstephenson]

Block backside:



Is there a napkin zip-tied around that leaky glob of mess?



Turbo: GarrettT3 from what I gathered from the numbers below and a post here from ten years ago. Is this a good mate to motor?





Engine Code: Brass toothbrush and brake cleaner produced this bunch of nothing. I am going to try and polish with either 600 sandpaper and/or brush fitting for dremel. Any sure fire suggestions will be applied.



Oil has been changed to the Rotella T6 synthetic and gear box is next along with radiator (coolant test showed poorly).

Michele

[vanbcguy]

Completely flush the cooling system and run VW G12 or later for the best results. The pink VW stuff is considered a lifetime fill - it basically doesn't go bad. It'll last the lifetime of the water pump, keep everything super clean and preserve all the plastic parts.

Where does the oil drain run to? The T3 does suggest someone reused 1.6TD parts, so if it drains to the pan that'd pretty much confirm Andrew's suspicion that it is a 1Y with turbo stuff bolted on.

The good news is the 1.6 T3 is actually much better suited to a 1.9 than it was to the 1.6. It was always an oversized turbo for the 1.6 so the extra displacement does it well.

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[libbydiesel]

The zip-tied napkin was good for a laugh.  I'm not sure I understand how that was supposed to work.  At least that should be an easy fix.  Get a new piece of hose of the right ID and length and use some sealant when you clamp it down.  If done right, it won't leak.  Make sure the hose is rated for oil and 300°F.

Some of the blocks are not stamped.  At this point I'm convinced it's a 1Y and you'd have to pull pistons/rods to confirm and there's no point in that.

As vanbcguy said, it's a T3 turbo from a 1.6. 

Fix the valve cover leak and the oil return line and it should be a good rig.   

 

[mstephenson]

ok. Fixing the napkin is on the list. 

So, to recap/conclude this thread and move on researching the other thread sections:

BLOCK: 1Y (with 98% certainty)
HEAD: 1Y

This makes me happy ! Thank you !

TRANS: ? 020 or 02a ? I’m confused since the code was scraped off.

And here’s a pic of what this little soldier sits in:

[libbydiesel]

I don't know if there is a difference between the AAZ and the 1Y heads.  Valves might be different.  It probably came as a long block, though, so it probably matches the block.

Trans is an 020.

[vanbcguy]

Pretty sure the 1Y has oil squirters for piston cooling and everything - I do know they used different pistons and rings than the AAZ but I wouldn't be concerned about that at all.

What you have is probably a forklift or generator engine as I don't believe VW ever put the 1Y in a car in Canada or the US. They definitely did in the UK but not here. Nothing wrong with that at all - VW builds lots of industrial engines. The injection pump is what makes it work in an automotive application and you have that already.

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[SR Heer]

Are we sure about the oil squirters coming with the 1Y - 1.9D NA diesel motors?
I know the 1.6D NA motors did not have oil squirters where as the 1.6TD turbo motors did.

[vanbcguy]

Are we sure about the oil squirters coming with the 1Y - 1.9D NA diesel motors?
I know the 1.6D NA motors did not have oil squirters where as the 1.6TD turbo motors did.

VW started putting them on even some of their gassers in the 90s.

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[libbydiesel]

The 1Y has oil jets.

[mstephenson]

I have a question about about the water pump and anti-freeze.

The motor was built in 2001 and I was told approx 40k miles driven. When I flush and replace the coolant w/ VW G12, should I replace the water pump as well?

I realize this is not the correct place to ask so thank you for indulging.

-m