Date: Thu, 14 Jan 1999 18:43:15 -0500
Reply-To: Martin Jagersand <jag@CS.YALE.EDU>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Martin Jagersand <jag@CS.YALE.EDU>
Subject: 1.9l TD swap, Was: Re: VW I-4 Engine Blowout
> From: Michael Avrea <>
> << 1.9 Turbo Diesel longblock with 1.6 intake ports (for putting
> 1.9l TD into the diesel Vanagon) $1500 >>
> I have a 82 Diesel Vanagon in good running order. What will be
> necessary in additional parts and labor (hours for a qualified
> mechanic), to get this motor up and running in my Vanagon?
> Thanks,
> Michael Avrea
You can put it in either with our without a turbo. Without a turbo
it's not much more complicated than swapping tre stock engine for
a rebuilt. Only difference is that the injection pump sits a bit
differenty on the 1.9's and you need to stretch the injection lines
a bit. Could make them break. Also check if Ken will give you a
new vaccum pump. I seem to remember that it's drive gear from the
intermediate shaft is different between the 1.9 and 1.6l. A mechanic
should be able to do this swap for $2-300. Or you could do it
easily yourself in a weekend. Only special tool needed is a
dial gauge to set the timing, borrow or buy for $15. Engine
drops down. No engine hoist needed, just wood blocks. Drop engine.
Raise van on blocks. Pull out engine. Installation is reverse.
To build it as a TD you need a turbo, intake and exhaust manifolds,
various oil lines, oil filter fitting (that's where the turbo
oil feed comes from). TD injection pump. (The old pump will work,
buit doesn't have the boost pressure aneroid, on the other hand with
the TD pump you have to modify the motor mounts to make it fit
under the lid) All this can be had from a wrecked VW TD car.
In addition you need to custom make:
* Turbo oil return line. (Goes to the block on the 1.9l, not the
pan as in the 1.6)
* Air box and air hoses (easy to do)
* Exhaust system. (Go as straight through and big as possible)
* Left motor mount. (Unless you're lucky to find the manifolds off a QTD,
rare)
I have posted links to drawings and descriptions of how to make
various of these parts. See the archives.
For those contemplating the 1.9 with the real 1.9l head you also need
to either:
1. Buy a new (can be had used in Canada) intake manifold. $250 from
VW.
2. Or weld more material onto your existing manifold, cut out to
match the BIG D-ports of the new manifold, and machine (flycut) it all flat
again. Local guy here did that. A bit tedious, and it is difficult to
mount the manifold into the milling machine.
The advantage of the new head is not only the big ports, but also bigger
valves, and while most 1.6l TD heads are solid lifters (need adjustment)
the 1.9 is hydraulic.
BTW $1500 brand new is a darn good price.
/Martin
--
Westy 1.9l Turbo Diesel
Quantum 1.6l Turbo Diesel
Martin Jagersand email: jag@cs.yale.edu
Computer Science Department jag@cs.rochester.edu
Yale University
Slow down and visit the VW diesel Westy page:
WWW: http://www.cs.rochester.edu/u/jag/vw
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