Yeah, I know ya, we go back a ways. I'll try to help.
So the 1Y is the NA (non-turbo) version of the AAZ right?
Both are IDI?
I'm not sure how much taller the 1.9 is.
I've heard it's the block that is taller so you might be right about everything above the injection pump mounting bracket being taller.
So I don't think the injector lines from the 1.6 will work. Lots of bending and they don't bend easy or like it.
Someone on here recently bought a set of 1.9 injector lines that they were real happy with.
But I can't think who or which post.
I'm going in the opposite direction.
A friend had his AAZ throw a rod though the block on his MK2 jetta and I'm putting one of my old 1.6TD engines in it's place.
I can't image the head surviving that and still being in good shape.
I was thinking a mechanical head will fit on a hydraulic block.
But not if you are putting it on a 1.9.
The head gasket holes for a mechanical head are too small for the pistons.
So Cascade German says their cam will work on anything 1.9 including AHU TDI engines?
That kind of makes sense since they are all 1.9 engines.
I have heard the cams on the hydraulic heads were made of a metal that was too soft or not tempered right and it is common to find the lobes worn.
I'm not sure how the timing curve for the 1.6 pump will work with the 1.9.
You could probably swap the timing piston springs and washers from one pump to the other and get close to the same timing curve.
Oh that's right your engine didn't come with the pump.
If it gets clacky at higher RPMs you could put another washer in or find the proper spring size somehow.
Slight cracks in the prechambers can be scary they don't worry me as much as cracks in the head around the prechambers.
The 1.6 hydraulic head has way smaller prechambers so the compression will be high with a 1.6 in a 1.9.
Several people have swapped 1.9 heads onto the old 1.6 blocks and the compression was so low it wouldn't start on a cold day.
I pulled a 1.9 prechamber once and it was at least twice the size/volume. Maybe triple. I could fit my finger in it quite a ways
So I'm not sure just a cam is the solution. Not sure what that high of compression would do to a 1.9D.
The expensive way to go:
https://tornau-motoren.de/en/e/EF/cylinder-heads/cylinder-head-complete?make=VW&model=GOLF%20III%20(1H1)&motorType=1.9%20D&carId=1866&powerKw=47&ccmTech=1896&yearOfConstrFrom=199111&yearOfConstrTo=199708 Didn't know AMC is still making heads.
I think the 1.6 cam sprocket and injectors will work.
Did the crank sprocket on the 1Y have the flat spot type keyway or the old 8mm wedge like the AAZ?
That was a trouble spot for the AAZ.
Pretty easy to upgrade to the flat spot and later TDI sprocket. I had a special tool made to broach it while the crank is still in place.
It will be interesting to see how the timing belt covers work out.
I can check with the guy and see how much of the AAZ parts he wants to sell or trade for 1.6 parts.
I'm a little short on 1.6 timing covers and am curious if the lower one is the same as the AAZ.
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