I've seen a couple online dealers with a "1.6 to 1.9 conversion kit" :
Convert 1.6 to 1.9 Diesel with our kit
Jetta, Golf, A1, A2, A3, A4,
Engine longblock, diesel convert from 1.6 to 1.9 THESE ARE NEW NOT REBUILDS. NO CORE! GET THE POWER AND FUEL ECONOMY AT THE SAME TIME! You must have some mechanical knowledge to make this switch as a few items muct be modified as the 1.9 is taller than the 1.6 but a qualified mechanic will find this very easy. This comes as a longblock only so you must transfer your pump and injectors etc. over to the new longblock. If you want us to do this we only charge $150.00 to change everything over. 69HP AT 4200 RPM TORQUE 95FT LBS AT 2500RMP
Conversion parts include:
timing belt
oil dip stick tube and dip stick
3 piece intake gasket
oil filter flange and gasket
intermediate gear
crank gear and bolt
vacuum pump
valve cover breather (PCV)
Anyone ever done this? Or have any details? Do we just put all of our 1.6 stuff on it and go?
As far as I know, as long as you get the block, all you have to swap is your manifolds, accessories, and injection pump + injectors. The kit appears to come with all other relevant stuff for the swap. The upgraded crank gear and bolt is the single most important thing on the 1.9.
I think the block is a NA, so I'm guessing all the rules apply for adding a turbo to it as with the 1.6 NA turbo adding. Keep it cool....
How much HP gain would there be over the 1.6TD? The reason I ask is my 1.6TD in a 4dr Sidekick is kind of a dog, I'd like to make it a bit quicker. I have some mods already, but still.
I'm not sure how ez it is to find these anymore, from what I understand, they quit building the 1.9NA in Jan. 2005. I got a few about 5 yrs ago for $1700 (New 1.9 NA Long Block) The TD's were complete, and $3200
Overland was the distributor, and I have a link to all their dealers, but can't find at the moment. All I've seen lately is the 1.9 TDI which they also offer, but are the newer block (not the 1Z), so mounts are different.
The 1.9 IDI (AAZ) is a 'drop-in', only being 16mm taller than the 1.6. the NA is ~66HP, and the TD ~74 (with the smaller 1.9 turbo) They all have squirters and are TD compatible (at least mine are) I got mine with 1.6 Hyd heads, so the intake manifolds of my 1.6's work. (The 1.9 has oval intake prots, and don't match (without welding and re-porting mainfold, GEX makes modified intakes, but Overland was providing 'adapter' plates on the later conversions.)
I really like the extra torque of the longer stroke, and still have a couple 1.9's that I will stick in a Westy and Samari. I can't seem to get as good economy w/1.9's (~42-44) as my 1.6's (44-48) But they are a good choice for Caddies too. I frequently tow over 1000# and use mine daily as a 'work' truck. (but I use a larger truck to tow my 'bulldozer' :oops: )
You will want a Turbo at your altitude. I keep several extra TD's around for when I move back to Colorado, from WA., but at 1000', I will stick with the NA's for 'longevity'. Tho very spoiled when driving the wife's TDI (B4 Passat @ 52 mpg)