Author Topic: 1.9TD IP swap in place of 1.6TD IP. Any issues? (Read 6668 times)

jtanguay · « **on:** November 27, 2006, 09:08:26 pm »

fitting a 1.9TD AAZ injection pump on 1.6TD. just bought it today!

I am wondering if someone has ever done this swap? looks like there are a few extra's (apply 12v to the altitude compensator thing, etc)

I have 2 extra 1.6TD ip's (one needs rebuild for sure, other one... probably too!)

anything other than the boost pin that I should swap over? has anyone ran into difficulties with a 1.9 pump on a 1.6?

i'm hoping to just tear my pump out, plug this new pump in (primed of course) and fire her up after timing it.

oh yea it has a plastic collar piece on the fuel screw... hmmm i might just melt it off for fun! :twisted:

hopefully that diesel leaking on my coolant hose hasn't softened it up too badly... haven't been driving the car for quite some time now, and I just miss the diesel!!! i neeeeeeed dieeeselll

thanks for the help guys!

jtanguay · « **Reply #1 on:** November 28, 2006, 05:58:27 pm »

well now that I'm thinking about it... isn't the camplate different in the 1.9 IP's??? but is that all I need to swap from the 1.6 IP

Blades · « **Reply #2 on:** November 28, 2006, 07:08:37 pm »

my buddy made it work, before the turbo on the 1.6TD went south.

Modified the 1.9 IP bracket to fit the 1.6TD bloc at his job (diesel truck shop :lol: )

Worked #1

jtanguay · « **Reply #3 on:** November 28, 2006, 07:19:09 pm »

makes sense that the bracket is different... thanks for the info! i have a parts car and have lots of pieces to play with

its really nice to be able to play around on a non rusty pump... i hate looking at rusty pieces with serial/part numbers all rusted out. plus they are just a huge mess!

now i have to allot more than a days work to install this pump (unless i get lucky) to get the bracket bit sorted out.

thanks again!

jtanguay · « **Reply #4 on:** December 01, 2006, 10:22:31 pm »

okay well informations i have learned.

- 1.9 ip will fit the 1.6 block
- 1.9 ip and sprocket must be used. 1.6 sprocket will not work.

yay me! lol

cant wait to get this thing installed and timed... i'm going to have a breakdown if i dont get this working soon...

RabbitJockey · « **Reply #5 on:** December 02, 2006, 06:13:44 pm »

should run real nice like

burn_your_money · « **Reply #6 on:** December 02, 2006, 06:45:20 pm »

Quote from: jtanguay

cant wait to get this thing installed and timed... i'm going to have a breakdown if i dont get this working soon...

May as well make a DIY while you're at it, and make sure to let us know if it was worth it

jtanguay · « **Reply #7 on:** December 03, 2006, 02:21:10 am »

my thoughts exactly burn... i got a real nice deal on the pump... and i wanna make use of it

.

if its just the 1.9 sprocket, then that is nothing... i was scare of brackets etc... who knows if a bracket i made would hold up? lol probably slide or something and mess my timing right up hehe... i have a lot to learn still.. :lol:

one thing i have just thought of... is the rev limiter/governor... i'm going to see a 4500 rpm power loss right? i dont even think i've taken my car that high except a few times to break the rings in... i kinda baby my car..

once i get the sweet tranny installed too, it will help immensely. i find that 1st gear in my car is useless... the motor winds up too fast and i'm not going that fast by the time 4k rpm hits. my last jetta was real nice... no tach but my trained ear had a pretty good idea of where the engine was at. the gears were much taller, but the boost didn't come on till 3k rpm.

if the governor will limit my rpm to 4300-4500 rpm, i will just live with it... i'm not even going to try and mess with that for the time being. need to understand how it really works first. maybe i will tear down my spare and run it off a drill just to see how the springs affect governor movement..

jtanguay · « **Reply #8 on:** December 03, 2006, 05:00:43 am »

well reading the diy guide for 'tweaking' the governor, it looks a lot simpler than i had imagined. but if i get the wrong length for the intermediate spring, my idle will be all screwed... right? maybe i'll look into it while my sprocket is being ordered

RabbitJockey · « **Reply #9 on:** December 03, 2006, 10:26:28 am »

you could always put the 1.6 governor on

jtanguay · « **Reply #10 on:** December 04, 2006, 04:20:48 pm »

hmmm about the 1.6 governor... i guess that could work

i'll see just how big my balls are if/when i decide to take a crack at it though... :lol:

i just went and ordered the parts i needed. got a spring washer, the retaining bolt, etc... pretty much everything on etka to hold the sprocket on, and the sprocket itself. even the little woodruff key

there wasn't a special one i was supposed to buy right? such as a 1.9 from 93 rather than 97?

oh and i checked the retail price on a pump... $3300... damn i got a good deal!

andy2 · « **Reply #11 on:** December 04, 2006, 05:25:34 pm »

Does the inj pump housing have threads or slots for the 3 mounting flange bolts?

I have a spare 93-95 pump mounting bracket and probably sproket too.For ordering the parts you would have needed to know which style pump you had 93-95 or 96-97?

jtanguay · « **Reply #12 on:** December 05, 2006, 12:32:18 am »

i told the guy it was out of a 97 jetta... hopefully my pump is from 97 and up, and hopefully the parts i am ordering will work!

hmmm maybe i will have to go see you andy, and check out my parts.

jtanguay · « **Reply #13 on:** December 06, 2006, 09:16:33 pm »

well met up with andy2 tonight... the pump will not work

its the 93-95 1.9TD pump. probably would have started leaking anyways... oh well...

the bracket won't even line up properly with the pump because of the timing advance cover in front.

the actual pump shaft sticks out considerably as well, and the 1.9 sprocket will not recess enough to compensate for it. modifying the pump sprocket and the bracket would work... but not if the pump is just going to leak down the road anyways...

well i was the test guinea pig... but at least we know now! should probably get some pics to better explain the issues... but i must retire!

andy2 · « **Reply #14 on:** December 06, 2006, 09:57:56 pm »

You didn't tell them the good part?? Modded pump and good turbo :wink:

Author Topic: 1.9TD IP swap in place of 1.6TD IP. Any issues? (Read 6668 times)

Blades

andy2

andy2