[Vwdiesel] Re: [Audi-VW-Diesels] 1.9td

[Dana Morphew]

When I put my rebuilt (BRC Racing custom pistoned) type 1Y into my '82 Caddy, the
only issues I had, outside of the rebuild itself, were:

1) having to make a 10 mm. spacer, out of aluminum plate, to go between the manifold
and downpipe, so the lower d.p. flange would clear the bracket for the steering rack
(As Loren can attest, before the spacer, I initially thought my tranny all of a
sudden lost reverse gear it knocked so).  This is using a [pre '81 (?)] four into
two diesel manifold with its d.p..

2) Since the 1Y is n.a., I cobbled together an intake using an AAZ manifold with 2"
i.d. vaccuum hose and cuff which brings air from a t.d. Quantum airbox that I
mounted on the  right fender.

I also installed a new 210 mm. LUK clutch.  I've got the load adjustment on the pump
screwed in as far as the limiter will allow and there is no, well...scarcely any,
smoke.  When I find a window I'll attempt to cut the limiter off, so I can optimize
a bit :).

Dana


James Hansen wrote:

> Okay... a question for the engine swappers out there.  What PITA should I be
> prepared for when trying to drop a complete 1994 A3 Jetta 1.9 litre td and 5
> speed trans into a Westmoreland wonder. I finally found a complete
> powertrain (it sort of found me), not super cheap, but in good shape with
> warranty.  I'll change clutch, rear seal and block heater first, but that's
> about it (the plan as it currently exists).  I know about the downpipe
> issues, will lay hands on factory one, or custom build as situation
> dictates. Anything else I should expect to rear it's head? Oh yeah, radiator
> size need to be bigger, right? The wiring is no trouble but if anyone has
> the round multipin plug that goes on the motor by the vac pump, I'd like to
> buy it.  It sure neatens things up to pull motor if need be. It looks so
> much like a tdi, I thought it was for a second or two...
>
> What to do about the 100mm axle flanges, any tricks?  Extend the splines on
> a 90 mm axle to hold the 100mm cv joint? Changing the outboard ones to 100mm
> sort of sucks in my opinion... they ain't broke...
>
> If anyone knows of anything else, a heads up will be much appreciated.  I'll
> be starting on it as soon as I get a buddy's car out of the shop- head
> gasket on same engine in 93 Jetta.  Now here's a strange one- I just drove
> this heap of his, out to the shop tonight from town.  I handles like you
> were trying to balance the car on a basket ball. It's so skittish it's
> dangerous, and he just loves the thing to death.  I'd better not let him
> drive our Passat, he'll never get back into his Jetta. Gonna have to inspect
> things well and check the toe. It's just nuts how lively it handles. very
> scary. Makes my A2 Jetta feel like it's on rails.
> Later
> -James
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