installing 1.9 head on 1.6 TD block

[chrissev]

Well I've finally managed to find a good 1.9 IDI head to put on my 1.6 TD block.  I currently have the head (rebuilt), the headgasket (metal) and the exhaust manifold.  I still need the 1.9 injectors, intake, and head bolts.  So I have a few questions for those of you who have done this before:

Can I use the cam pulley from the 1.6 head on the 1.9 head?  
Which head bolts do I use and which torque pattern do I follow?
Can I use the water spigots from the 1.6 head on the 1.9 head?
Will my KKK turbo bolt up to the 1.9 exhaust and intake manifolds?

Also, anyone in or near TO have a valve cover for a 1.9 IDI that they don't need?  I need one of those.  

Thanks for answering if you can.  There will no doubt be more questions as the project progresses.

Chris

[vwmike]

I haven't done this before, but here is what I think:

-Yes
-The head bolts are the same - follow the torque specs for the 1.9 gasket if you're using the 1.9 gasket (and you should be)
-Yes
-I don't know, but why not use the 1.6 exhaust manifold? I think the connection from the turbo to the 1.9 intake manifold will be the same

.

[935racer]

Don't think many people have done this swap, its just talked about alot. I have done it and there isn't much involved. Also use 1.6 injectors, than you don't need to switch your injector lines.

Can I use the cam pulley from the 1.6 head on the 1.9 head?  YES
Which head bolts do I use and which torque pattern do I follow? Same as 1.6.
Can I use the water spigots from the 1.6 head on the 1.9 head? YES
Will my KKK turbo bolt up to the 1.9 exhaust and intake manifolds? Exhaust manifold: if its a k24 no, if its a k14 yes. Intake : the stock manifold will work with whichever turbo the difference is in the rubber hose that connects them.

Chris

Why are you running a 1.9 head?

[chrissev]

Why are you running a 1.9 head?

because I have one and it's rebuilt and good to go.  price was right, and I've been told they fit.

[16V-Sauger]

you will get a very rough idle when cold  :oops: due to the to low compression ratio

[chrissev]

you will get a very rough idle when cold  :oops: due to the to low compression ratio

The mating surface on the 1.9 head I have purchased is flat.  There are no recessed areas where the valves are located.  It is one flat surface all the way across, the same as the 1.6 head.  The thickness of the metal head gasket is the same as the thickness of the fibre head gasket.  So I don't see any reason why installing this head would result in reduced compression, unless the holes in the metal head gasket are slightly larger than those in the fibre gasket, but surely that would give a very minimal amount of extra space.

[935racer]

you will get a very rough idle when cold  :oops: due to the to low compression ratio

Not true.

The compression difference is minimal and not noticable, the precups are only about .3cc larger. IF its a stock unmodified head you won't be having any issues unless you do something wrong yourself.

[chrissev]

you will get a very rough idle when cold  :oops: due to the to low compression ratio

Not true.

The compression difference is minimal and not noticable, the precups are only about .3cc larger. IF its a stock unmodified head you won't be having any issues unless you do something wrong yourself.

thanks for the advice.  Well I still have to get some head bolts, a valve cover, and 1 TD injector (have three working ones, and one bad one) then wait for some warm weather (-10 outside right now) then I can bolt this head on and see for myself how it works.  I'm very interested to see how this will turn out.

[935racer]

Let us know  The one nice thing is if you ever plan on makin some big power you got the hardest part of the job done, gettign a good 1.9 IDI head :cry:

[16V-Sauger]

its not my experiences, i just "copyied" some experiences here from a german race-team.

[935racer]

german race team with a 1.6/ 1.9 combo? More details pleasem, sounds cool

[16V-Sauger]

http://www.prga.de/

they used a mk1 with a completely modified 1.6l td and around 150hp. after blowing a few heads they decided to use a AAZ head. and they said that the idling was  very poor. got some better after making the glowtime some bigger.

maybe it was caused by using 100% saladoil  :lol:

[935racer]

Coudlnt; find any info on tht site about the 1.9head or anything, what the heck were tehy doign that was blowing heads??? SOudns liek they had soem otehr issues there. Thanks for the link!

[16V-Sauger]

http://f23.parsimony.net/forum49387/messages/165941.htm

sadly only in german

[935racer]

Yea I didn't really understand much of that, but it soudns liek they couldn't get it to run right, I didn't understand the names of the engine parts and stuf they reffering to when talking about the extr volume in the 1.9 head... I kinda caught somehting abotu they wanetd to use the thinnest gasket possible because they were scared of the extra volume = less comrpession.