maybe im to newb...

[lancer1978]

I tried searching a few times before asking this....(in a few diff. spots and general searching didn't bring me up the info I was desiring)
I have a 85' golf that the engine just died on(literally yesterday), and I am wondering how much of a headache is swapping in a 1.9aaz tdi engine? I found what seems to be a great deal on a full engine, injectors, pumps, newer turbo, intercooler, etc..
and im just wondering how hard it would be, I was talking to someone somewhat local and he did a conversion from gas to diesel in a cabby in under 8hours by himself, but mine is already diesel, So What I am really asking, how hard is this swap and is there any "how to's" to make this easier for a first time diesel owner? Any help is more then Greatly appreciated!!

[kane66]

good question... for another forum. Check out http://forums.tdiclub.com/forumdisplay.php?f=63 for tdi conversions. But to make a long story short It's not that hard as engine swaps go. But you have to decide what path you want to go down. There is the full electric swap where everything is removed from a doner vehicle, and slapped into the new vehicle. There is also the Mtdi way where the engine will look much like what you have in there with no electronics. Check out http://www.vwdiesel.net/forum/index.php?topic=6427.0 for info on tdi pumps.

[jtanguay]

the 1.9aaz is not TDI.  the aaz we have here did not come with an intercooler either.  if you have the aaz the engine will bolt right in, and i think all you need is either a custom downpipe, or find one from an AAZ and splice it into your current system.  the clutch from the 1.6 engine will need to be transfered to the AAZ to fit the 1.6 transmission, or you can stick with the larger clutch and stick in a mk3 trans, but the gearing is very similar anyways.

[Patrick]

Depending what his engine came out of, he won't even have to change the clutch. My '92 jetta has an AAZ with the bigger clutch it came with hooked right up to a mk2 trans.

[jtanguay]

Depending what his engine came out of, he won't even have to change the clutch. My '92 jetta has an AAZ with the bigger clutch it came with hooked right up to a mk2 trans.

yea you're right 24 spline.   the TDI uses 28 spline though.

[bigblockchev]

If I recall correctly there is a certain amount of percussive modification necessary to the shock tower in order to get the serpentine pully to clear. Other that that a piece of cake. Cheers Dan

[jtanguay]

If I recall correctly there is a certain amount of percussive modification necessary to the shock tower in order to get the serpentine pully to clear. Other that that a piece of cake. Cheers Dan

hmm i have the 1Z installed in my '92 mk2 without any modification... i did have the k24 on it though (everything bolted right up)