problems converting 1.6 gtd to 1.9 gtd

[GTD0023]

I just did a conversion from a 1.6gtd to a 1.9gtd and bumped into a few problems! :shock:

So the original engine was a 1.6 gtd '89. i wanted to do the transfer because i wanted more power and the old 1.6 oil consumption was very bad.
I bought a 1.9 td engine from a guy without IP and other stuff, just block and head! I did a complete overhaul on the engine and now it is like new.

THE PROBLEMS:

1. the turbo (garret T3) does not fit. it bumps on the intake manifold so doesn't go enough for the 4 bolts to fit.
What i did is just grind the side of the turbo and the intake manifold to create enough space. I saw someone on the forum made an adapter but the grinder was the easiest way out! :oops:
PROBLEM SOLVED!

2. The backplate for the timing cover from my 1.6 does not fit on the 1.9. I guess this is because the block is taller
Solution for now: Drive without a timing cover :cry:
Any suggestions on this???

3. I also did not get a dipstick with the 1.9 engine so i gotta use from the 1.6. The question is : How much oil does this 1.9 engine take.
Please can someone give high and low level oil quantity, so i can make my own marks on the dipstick??

4. I had to use the IP from the 1.6 and bend the fuel lines a bit.
Is this going to be a limitation for performance?? Is the 1.6 pump going to deliver enough fuel for the 1.9?

Help!!!!

[zukgod1]

I just did a conversion from a 1.6gtd to a 1.9gtd and bumped into a few problems! :shock:

So the original engine was a 1.6 gtd '89. i wanted to do the transfer because i wanted more power and the old 1.6 oil consumption was very bad.
I bought a 1.9 td engine from a guy without IP and other stuff, just block and head! I did a complete overhaul on the engine and now it is like new.

THE PROBLEMS:

1. the turbo (garret T3) does not fit. it bumps on the intake manifold so doesn't go enough for the 4 bolts to fit.
What i did is just grind the side of the turbo and the intake manifold to create enough space. I saw someone on the forum made an adapter but the grinder was the easiest way out! :oops:
PROBLEM SOLVED!

2. The backplate for the timing cover from my 1.6 does not fit on the 1.9. I guess this is because the block is taller
Solution for now: Drive without a timing cover :cry:
Any suggestions on this???

Run without it if you don't have/ cant find one, just keep your finger out of it

4. I had to use the IP from the 1.6 and bend the fuel lines a bit.
Is this going to be a limitation for performance?? Is the 1.6 pump going to deliver enough fuel for the 1.9?

Help!!!!

   

It will be ok but the 1.9 AAZ cam plate has a higher lift. So ya it will work but you would be better off getting an AAZ cam plate for your 1.6 pump and maybe a larger pump head as well.

[jtanguay]

i think it was veeman who had sucked up a plastic bag while on the freeway and then made his timing belt slip because he didn't have the cover on.  man that is some BAD luck!  but just warning you of what can happen without it on.  the chances of that happening are pretty slim though.

[zukgod1]

Could run the plastic piece on the bottom?
That would lessen the chances allot I bet.

[GTD0023]

ok, so the only difference between the 1.6 and the 1.9 ip is the camplate.
I just have to find myself a better camplate and head.

I have some ip's here but not from vw. they are bosch pumps.  let's say i take them apart , how do i know which one is better compared to mine.
where do i measure or something else??

[zukgod1]

You can use a caliper to measure the plunger and it needs to be a 4cyl pump. On the cam plates I wouldn't use anything non VW on the cam though. That's where the timing comes from.

[saurkraut]

I had a bird strike @ 80+mph that put bird parts and perhaps some grill that got into a fully installed timing cover (inside and outside covers) and make the pump retard on tooth.

Holy ski high boost and EGT Batman.  Ran like crap too.

[zukgod1]

I had a bird strike @ 80+mph that put bird parts and perhaps some grill that got into a fully installed timing cover (inside and outside covers) and make the pump retard on tooth.

Holy ski high boost and EGT Batman.  Ran like crap too.

Wow, got any pictures of that?

Sounds nasty..

[RabbitJockey]

i think it was veeman who had sucked up a plastic bag while on the freeway and then made his timing belt slip because he didn't have the cover on.  man that is some BAD luck!  but just warning you of what can happen without it on.  the chances of that happening are pretty slim though.

he was missing the lower cover tho.

[GTD0023]

the problem with using the 1.6 timing cover backplate is that the 1.9 block is taller and so the ip bracket is lower. so on the backplate if you match the hole for the camshaft, the hole for the tensioner and the ip don't match up, the holes are higher.
I guess i just have to live with that for now, untill i find myself a 1.9 backplate and timing cover!

So does anybody know how much oil the 1.9 gtd takes?? high and low level??

[LoneWolf]

if you get really stuck with the turbo, just use the 1600 one, itll bolt up to the oil feeds, but youll have to plimb the water return into your return pipe for the heater matrix.

 youd be far better getting all the timing-belt covers, no point risking it if youve put so much work into it.

 incidentaly, how much did you pay for the block and head, if you dont mind me asking?


  Matt

[Sierra94]

I donīt see any problems using the 1.6 dipstick as the oilpans etc are interchangeable with the 1.9. The 1.9 engineblock is a little higher than the 1.6 but the bottom is just the same.

The 1.9 oil specs are 4-4.5 liters depending on oilcoolers and filter size.

Someone correct me if Iīm wrong  :wink:

[GTD0023]

how much did you pay for the block and head, if you dont mind me asking?

the bare engine cost me $250.
but all the new parts i put on it cost me 3 times that amount!!