Zeke Gets a TDI Swap (VW Mk4 1.9 ALH Manual). (2 Viewers)

[AirheadNut]

Man, replies like the one you just made are why I love this place. You've given me a ton to think about. I'm after a balance between performance and reliability. I've read through a lot of your thread and it seems that you landed in the sweet spot. Thank you so very much for the input. I'm grateful. When I get into this, I'll be hitting you up for advice... I owe you a beer someday... at the solid axle TDI swapped summit!

Balance of power and reliability is exactly what I've been chasing too, but I'm not too sure about hitting the sweet spot quite yet! What I suspected to be failed valve stem seals may actually be worn piston rings. Early on after the swap I installed a set of no-name injectors that way overfueled on a couple of cylinders and probably caused some long term damage that is beginning to show up now. I may be on the hunt for a replacement engine myself soon...

For reference, there were times when I had trouble maintaining 65mph on flat highways without being over 1300ºF EGT, and 1400º+ was a common occurrence on small hills and with a headwind. After replacing the injectors and getting a better tune temps are way better, at 70mph it is closer to 950-1000ºF and I rarely see over 1300ºF pulling hills. The damage was probably already done, though.

 

[bobm]

Me guts a Headache

 

[Frankster]

Hi. I'm currently busy with a similar swop for my FJ60, also with the H42, 4 speed. Only difference is that I went with a mechanical pump on my 1.9tdi and the engine code is AHF. My concern is the gearing and trans ratios with the 31s. Looks like I will be doing about 3k rpm at 70mph. Not a big issue really as the vehicle is heavy and the revs will keep temps in check. I'm not in the US so I'll be making my own adapter. Good luck with your build!

 

[Old Nick]

Balance of power and reliability is exactly what I've been chasing too, but I'm not too sure about hitting the sweet spot quite yet! What I suspected to be failed valve stem seals may actually be worn piston rings. Early on after the swap I installed a set of no-name injectors that way overfueled on a couple of cylinders and probably caused some long term damage that is beginning to show up now. I may be on the hunt for a replacement engine myself soon...

For reference, there were times when I had trouble maintaining 65mph on flat highways without being over 1300ºF EGT, and 1400º+ was a common occurrence on small hills and with a headwind. After replacing the injectors and getting a better tune temps are way better, at 70mph it is closer to 950-1000ºF and I rarely see over 1300ºF pulling hills. The damage was probably already done, though.

Oh, man, that is a real bummer. It's clear that I still have a lot to learn.

I'm hoping that with the money that I saved with the $450 Jetta to give the engine a lot of attention and upgrades.

 

[Old Nick]

Hi. I'm currently busy with a similar swop for my FJ60, also with the H42, 4 speed. Only difference is that I went with a mechanical pump on my 1.9tdi and the engine code is AHF. My concern is the gearing and trans ratios with the 31s. Looks like I will be doing about 3k rpm at 70mph. Not a big issue really as the vehicle is heavy and the revs will keep temps in check. I'm not in the US so I'll be making my own adapter. Good luck with your build!

View attachment 3991995

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hoping that the swap goes well. When you get your build thread going you're welcome to put a link in here.

 

[Old Nick]

Got a bit more done on Zeke yesterday. Making sure to take my time and document what I'm pulling and what goes to what.

The airbox on the ps side, finally gave up its cover, but I'm having a dang hard time getting the nut pulled off of the retainer... just on the cabin side of the firewall.

Does the dash need to come out to access that bolt/nut?View attachment 3988057

Alright… half of the engine bay is empty. Small steps, but headed in the right direction

 

[Old Nick]

Thank you, brother. That’s just what I was after.

Just wanted to say thanks again for sharing knowledge. Helped
Me out big time

 

[Old Nick]

Draining all fluids. Hoping to get the radiator pulled today.

 

[Old Nick]

Moving right along.

 

[bobm]

Nucked

 

[J Mack]

Nucked