Recent Posts

71

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by fatmobile on May 18, 2026, 10:08:25 pm »

 I believe it had a D on the end of the part number. I remember because it is D-shaped.
 But that might have gotten superceded with an E sprocket.
It's the sprocket for the AHU engine and does fit the 1.6.

I'm not sure how many shops can put the proper flat spot on the end of the crank, if the crank is off the engine.
 I had a shop try and made it too sloppy for my liking.
 So I had a fixture made that would hold the broach steady and cuts it to the perfect depth.
 you actually kinda have to tap the sprocket on.
It works with the engine still in the car.
Just lent it to my friend in MPLS he used it unsupervised and it worked great for him.
 I've thought about renting it out, but I'd need at least a $500 deposit (I'm not sure I could get another perfect one made for that much) and $50 for the rental.



crankkeywaycutter_2 by vwfatmobile, on Flickr

72

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by VWSmokr on May 17, 2026, 11:11:33 am »

Not trying to knock the OP's topic astray, but fatmobile... your statement, "Pretty easy to upgrade to the flat spot and later TDI sprocket." has even broader interest for any who do not wish to re-experience the 'mangled keyway' saga on another engine... EVER!  So, 1) What is the correct part # for the "later TDI sprocket"?  2) Will it fit an IDI 1.6n.a. / 1.6td crank? and  3) Can most automotive machine shops accurately broach/machine a 1.6L crank to fit such a sprocket?

73

General / Re: Internally Balanced Crankshaft?

« Last post by VWSmokr on May 15, 2026, 01:38:43 am »

In 1987, VW Jetta was not offered with any TDI engines, only IDI. However, it seems that you may be asking if, for a Jetta TD engine, an EXTERNAL (weighted & indicated as to position) damper or flywheel is needed to achieve a balanced reciprocating assembly (as is common on many Detroit-built domestics). AFAIK... No. They are all supposed to have the INTERNAL components balanced together. OTOH a $erious performance assembly, especially one intended for high rpm service, could include any damper/pulley, as well as the flywheel & clutch assembly in the balancing process.

74

Parts for Sale/Wanted / Re: WTB: AAZ Stuff Injector hard lines and Full Timing Cover 3pc set

« Last post by fatmobile on May 14, 2026, 10:09:05 pm »

 My buddy had a rod go through the block on his AAZ.
I'm going to see how many parts will swap over to a 1.6.
He said I could sell the leftover parts to you.
Craig

75

General / Re: Internally Balanced Crankshaft?

« Last post by fatmobile on May 14, 2026, 10:02:39 pm »

I am not sure what that means.
 It is balanced.

76

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by fatmobile on May 13, 2026, 09:24:19 pm »

Looks like the 1.9 lines came from brickworks:
https://vwdiesel.net/forum/index.php/topic,47169.0.html

77

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by fatmobile on May 13, 2026, 09:19:11 pm »

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.

78

Parts for Sale/Wanted / WTB: AAZ 1Y Stuff Injector hard lines and Full Timing Cover 3pc set IM pulley

« Last post by vwpieces on May 13, 2026, 10:26:06 am »

Pretty much found everything on the list.

Thanks RabbitJockey.

79

IDI Engine / Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by vwpieces on May 13, 2026, 02:18:05 am »

I have been running 1.6L TD's in a MK1 for 20+ years and know those pretty well. Also have Spare Parts.
A few months ago a 1Y short block came my way. Nice condition too. I want to use "what I have" if at all possible.
How much Taller is the 1Y compared to the 1.6TD? and am I correct in thinking the height difference is all above the IP mounting bracket holes on block?

Only 1.6 hydraulic head in the hoard is not great to say the least. It is flat but the usual cracks between seats. And there are hairline cracks in the prechambers. And the cam has pits starting on 4 lobes. Exhaust valves are Real Hard to find in USA, But I dug deep and found Int and Exh valves. Did New guides and cut the seats, I already had a new set of the INA 034****** lifters... just need a cam. Finding an 068109101L cam in USA, good used or New has eluded me. I have taken some basic measurements, comparing an 068109101W solid to the L and other than slight ramp difference, W is very slightly flatter as it approaches the lobe tip. I ALSO see PartsPlaceInc selling One cam for solid and Hydraulic heads... The cheepAss in me wants to just put the W in the Hyd Head.

As for a cam, I did see Cascade German has a cam they say will work on a 1.6L It is the 028109101F, 028109101C, 028109101G, Stock Eurospec camshaft for all VW TD AAZ and TDI 1Z/AHU engine codes.
Note: On AAZ's you will need 1Z/AHU valves and spring.
Fits the following:
1996-1998 Jetta, Passat, Golf TDI
1993-1996 Jetta, Passat, Golf TD (AAZ)
Also fits 1.6L TD - read on TDIclub and VWdieselparts on how these work in 1.6L engines! You would want to get our hydraulic lifters to go with it too!
As quoted from the ebay listing.
So is this a drop in cam for the 1.6 hydraulic head? I searched all those part numbers on this site and nothing 1.6 head related.

Or should I just give up on a Cam for the 1.6 and buy a complete Chinese AAZ Head off eBay for $260 to $320

Other parts I have and would want to use if possible
1.6TD pump with LDA
Have a spare set of 1.6 TD 155bar injectors I have new nozzles in and pop tested.
I think the 1.6 TD injector hard lines are a possibility? or AAZ?
Conti timing belt 028109119P
068 head bolts and timing belt tensioner I already have and I think are correct to use.
Piston protrusion is 0.9144mm and I believe that is 2 Notch, 028103383BKJ,  ELRING 914856
Using the 068 cam gear, pump gear OK? Crank timing gear is the one from the 1Y.
Pretty sure None of my timing belt covers will work and I have some MK1&2 types on hand.
I should be covered for clutch/flywheel in 200 or 210 if I want to go there.
Misc gaskets and seals I should have, but oil filter housing to block I might not have, with the offset top hole.

I know a couple guys from vortex will recognize me.
Thank you in advance.

80

MK2 Golf/Jetta and Audi 5k / Re: AC and PS v-belt configs

« Last post by fatmobile on May 07, 2026, 08:42:47 pm »

If you put the alternator where the AC is in the top 2 and use the same blue belt.
If you have a picture of the alternator, you'll see 2 holes on the opposite side of the pivot bolt.
I'll try to get a picture but it won't be until next week.