1.9TD It's alive

dokarex · Posted: Tue Apr 01, 2008 1:57 pm Post subject: 1.9TD It's alive

Wish me luck, we are going to put my new 1.9TD into my Doka tomorrow. Very Happy

Will let you know when it's running and how much of a PITA it was.
_________________
1987 Doka 1.9TD from Germany gasser DU tranny, fuel turned up, 1.6 LDA pin, boost at 15 psi,egt and boost gauges,stock diesel tach,air filter behind passenger tail light, IC to come
2006 Jetta Wagen 1.9TDI
B6200 Kubota Diesel
16ft Freestyle catamaran
16 ft Sunray 85 Horse (sunk)

bd · Posted: Tue Apr 01, 2008 2:50 pm Post subject:

good luck! I can't remember from your previous posts...what engine are you replacing? A 1.6na?
_________________
1990 2wd TriStar, Oettinger-tuned 1.6L TD

coolwind57 · Posted: Tue Apr 01, 2008 4:27 pm Post subject:

I'm very interested in what 1.9TD you ended up acquiring and how the installation went. Give me details, details!!

Good luck, man.
_________________
1983 Vanagon Diesel L
NA 1.6, 5-speed Manual
Burning Waste Vegetable Oil, baby!!

kayakwesty · Posted: Tue Apr 01, 2008 5:45 pm Post subject:

a post without pics is useless... Very Happy

please post some pics...I want the same conversion!
_________________
1984 Westy 2.0 Jetta ABA Motor/1.8 head converted to auto tranny, with 180,000 on body, 55K on engine and transmission

B.5.5 Passat Wagen with 30v V6-67000 Miles

DAS AUTO

CHANGE YOUR FUEL LINES!

A post without pictures is useless

http://www.kayakwesty.com

http://www.waldensridgewhitewater.com/

dokarex · Posted: Tue Apr 01, 2008 5:58 pm Post subject:

Yes I'm replacing the 1.6NA with a 1.9TD from a 1995 VW Golf with only 74 000 km (46 000 miles).
I'll try to get some pics. Very Happy

_________________
1987 Doka 1.9TD from Germany gasser DU tranny, fuel turned up, 1.6 LDA pin, boost at 15 psi,egt and boost gauges,stock diesel tach,air filter behind passenger tail light, IC to come
2006 Jetta Wagen 1.9TDI
B6200 Kubota Diesel
16ft Freestyle catamaran
16 ft Sunray 85 Horse (sunk)

Williamtaylor33 · Posted: Wed Apr 02, 2008 9:40 am Post subject:

is this the diesel with the AZZ engine code?
b/c thats what i thinking of putting in mine.
_________________
89 Bostig powered syncro westy

dokarex · Posted: Thu Apr 03, 2008 9:23 am Post subject:

It's alive!!!!!!!!!!!!!
I now have a running 1.9TD AAZ in my 87Doka Very Happy

It took about 9 hours to switch from my 1.6NA to the 1.9TD, and that was mostly just pulling the engine and switching things from the 1.6 to the 1.9
oil pan and pickup, pulleys (from serpentine to just running water pump and alt), timing belt cover, clutch, making a new pilot bearing switching the coolant outlets on the engine to the old (1.6)ones so I could use the old wiring.
Installing and wiring took about 2 hours, after switching everything over and an hour this morning to install the fuel lines and self bleeding filter (standard 92-97 fuel filter), hook up the battery, fill oil and time to start it up .
Turn the key and nothing Crying or Very sad

Just the wire that slips onto the solenoid, it had broken the connector when we pulled the starter bolts out to drop the engine.
Fixed that
Turned the key
About 10 seconds of turning over and it fired up Very Happy

Bleed the coolant
Drove up the biggest hill in town and it was still accelerating up the hill in 4th gear and easily held 90KPH (speed limit 50) up the hill Very Happy

This hill use to mean shifting into 3rd and still barely holding 60KPH Very Happy

Now all I have to do is route a new air cleaner and install a muffler.

If you have a Diesel van DO THIS RIGHT AWAY , if you can find a 1.9TDAAZ It was quite an easy switch (not really a conversion?) and the power difference is definitely worth it. If you have a gas van and can find a Diesel bell housing DO THIS RIGHT AWAY. I'll let you know what my mileage is as soon as I figure it out.

I WILL NO LONGER BE PLOTTING ROUTES TO AVOID THE HIGHWAY Very Happy

WISH LIST: gas transmission (The gearing will better suit the power of this engine), intercooler, adjusting the fuel screws (www.vwdiesel.net) more power, WVO conversion (unfortunately I don't drive very far but want to do this any way Cool

) and of course finishing the body work and paint.

Very Happy

Pictures to follow
_________________
1987 Doka 1.9TD from Germany gasser DU tranny, fuel turned up, 1.6 LDA pin, boost at 15 psi,egt and boost gauges,stock diesel tach,air filter behind passenger tail light, IC to come
2006 Jetta Wagen 1.9TDI
B6200 Kubota Diesel
16ft Freestyle catamaran
16 ft Sunray 85 Horse (sunk)

coolwind57 · Posted: Fri Apr 11, 2008 6:14 pm Post subject:

Super post, man. Thanks for sharing. I just got off the phone with the guy in California that's known for importing such engines from Germany. I'm freakin' doing it, that's all there is to it.

We'd sure love to get some pics.

Didn't you have to shave a millimeter or so off your block somewhere? It seems I've read that somewhere. Was the IP and all of its cables/lines pretty much a direct replacement too?

Thanks again and congratulations!
_________________
1983 Vanagon Diesel L
NA 1.6, 5-speed Manual
Burning Waste Vegetable Oil, baby!!

dokarex · Posted: Fri Apr 11, 2008 7:36 pm Post subject:

no mods at all to the block
This was installed in a Doka so I have more clearance then in a westy but if you switch over your throttle control arm and the C-bracket?that the throttle cable mounts into ot look like youu shoudn't have any (or too many) clearance problems.
I'll get the pics up soon and will include one of how close the IP comes to what would be the floor in a westy or regular van.
_________________
1987 Doka 1.9TD from Germany gasser DU tranny, fuel turned up, 1.6 LDA pin, boost at 15 psi,egt and boost gauges,stock diesel tach,air filter behind passenger tail light, IC to come
2006 Jetta Wagen 1.9TDI
B6200 Kubota Diesel
16ft Freestyle catamaran
16 ft Sunray 85 Horse (sunk)

Vanagon Nut · Posted: Fri Apr 11, 2008 7:47 pm Post subject:

mr_vanagon · Posted: Fri Apr 11, 2008 8:26 pm Post subject:

Lemme save somebody a click.

Image may have been reduced in size. Click image to view fullscreen.

_________________
'68 Autostick Bug Mom bought new
'89 Tintop Vanagon Dad bought new

the caveman · Posted: Fri Apr 11, 2008 8:30 pm Post subject:

Yeah it's nice but it's gas. You gotta go mTDI all the way.

Vanagon Nut · Posted: Fri Apr 11, 2008 8:41 pm Post subject:

Vanagon Nut · Posted: Fri Apr 11, 2008 8:42 pm Post subject:

mr_vanagon · Posted: Fri Apr 11, 2008 9:05 pm Post subject:

?Waldo? · Posted: Fri Apr 11, 2008 9:05 pm Post subject:

Vanagon Nut · Posted: Sat Apr 12, 2008 9:30 am Post subject:

Thanks guys.

One reason I didn't bother learning how to post pics was I assumed that too many images would start to eat up HDD space in the archives. But then again, personal web sites come and go, so images posted here likely stand a much better chance of surviving.

Neil.
_________________
1981 Westy DIY 15º ABA
(VW Gas I4)

1988 Westy DIY 50º ABA

VE7TBN


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