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

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Old Nick said:
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!
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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.
 
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!

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AirheadNut said:
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.
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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.
 
Frankster said:
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!

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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 said:
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
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Alright… half of the engine bay is empty. Small steps, but headed in the right direction
 
Old Nick said:
Thank you, brother. That’s just what I was after. 🍻
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Just wanted to say thanks again for sharing knowledge. Helped
Me out big time 🍻
 
Draining all fluids. Hoping to get the radiator pulled today.
 
bobm said:
Zeke update HIHO 😘
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Nothing happening since the last pics 😢

Spent a ton of time getting the last bugs worked out of my wife’s 80. I promise… it’s happening this Spring. Just need the weather to warm up a bit.

Collecting bits and pieces and getting things organized.
 
Howdy, Gents!

Hoping that all of you are doing mighty fine this Sunday evening/afternoon.

A big shout out to @surfpig for hooking me up with some Piggy goodies. The Zeke build/swap got waylaid badly by finishing up my wife's 80 (I use the phrase "finishing up" loosely, as there's always something else to do on that rig). But, it's looking like I'll be able to get back to Zeke in the next couple of weeks. @120mm I'll keep you posted as I get closer to pulling the 2F

I'm selling my trusty old FJ62 to fund the build properly. I don't do debt, so having cash on hand from the sale will make things with Zeke much easier, and hopefully a little quicker. And, it will also allow me to pick up a new 5sp w/ split transfer case, a big ol' turbo and all of the other TDi components that I'll need as the build progresses.

Need to pull Zeke's front apron to make the engine pulling and swap easier to manage.

No pics yet. But... soon.

Cheers, Fellers.
 
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