*DISCLAIMER, THIS IS BASED ON MY PERSONAL EXPERIENCES, I DO NOT RECOMEND OR GUARENTEE THIS WILL WORK THE SAME FOR YOU! IT IS ALWAYS BEST TO FIND THE PROPER HEAD FOR YOUR ENGINEThis section is dedicated to the 1.5L (1977 – 1980 engine code CK) and the early 1.6L (1981 and some early 82 engine code CR). These are mechanical lifter engines with 11mm head bolts
First and foremost if you have either of these engines read this thread first!
http://www.vwdiesel.net/forum/index.php?topic=21948.0Moving on. The differences we need to concern ourselves with when talking of a head swap are the size of the front center oil return port, the longer stroke of the 1.6 and the swirl chamber volume.
The 1.5L originally had 23.5:1 compression whereas the 1.6L originally had 23:1 compression. The 1.5 has slightly smaller precups, which yield a volume of about 11.5cc above the piston at TDC. The 1.6 has about 12.8cc.
If one were to swap a 1.5 head on a 1.6, couple the smaller precup with a longer stroke and that would yield approximately 25:1 compression. Although this makes for some easy cold starting there are no other gains to be had from this, if anything it would rob you of power, economy, and durability.
Likewise if you were to swap a 1.6 head on a 1.5, couple the shorter stroke and larger precup that would yield approximately 21:1 compression. This would be the better of these two situations, although this could result in some difficult starting in cold temperatures…
Compression issues aside, there is also the matter of the front center oil return passage. Remember that a 1.5 has a smaller passage than a 1.6. There is a simple solution to this. One would need an adapter similar to this one
http://www.vwdieselparts.com/1.5-1.6.htm. If installing a 1.5 head on a 1.6 block this would be installed in the block, and a 1.5 head gasket would be needed. If you were installing a 1.6 head on a 1.5 block this would be installed in the head, and a 1.5 head gasket would still be used. Some have attempted to “goo” the gap left with RTV or JB Weld, but long term this is usually an unsuccessful fix… There would also be the option to weld the hole so that it is smaller, for most this would be more so difficult.
Pictured Below is a 1.6 head with a 1.5 gasket placed on it.. Note the gap