A 1.6TD and a 1.9TD have the same mounting flanges on the exhaust and intake
manifolds, so it is possible to mount a 1.6TD turbo and manifold on a
1.9TD - actually it is probably best to do this - keep the 1.9L intake
manifold though!

The 1.6TD - at least the Golf Jetta have a larger turbo than the 1.9TD.
These turbos really perform if you mount it on a 1.9 block and increase the
boost pressure to about 14 to 15 PSI.  Also, you should take the 1.6L
injectors and the injector pump and install it on the 1.9 block.  The 1.6L
injectors / pump operate at a higher pressure and will give you more power
as the 1.9 was built for good emissions and the 1.6 for power.  I have
documents here from Germany stating 85hp without an intercooler and without
increasing the boost beyond the factory 10PSI.

The only problem that you are going to have is the oil return line - you
will have to attach the 1.6 end to the 1.9 pipe.

David Marshall

Fast Forward Automotive Inc.
4356 Quesnel-Hixon Road
Quesnel BC Canada  V2J 6Z3

http://www.fastforward.ca    mailto:sales@fastforward.ca
Phone: (250) 992 7775        FAX: (250) 992 1160

- Vanagon Accessories and Engine Conversions
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-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com]On Behalf
Of Tromper
Sent: July 29, 2003 11:27 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: Turbo Diesel 1.9L mounting in a Westy

I wonder if you couldn't mildly port a quantam or audi TD
manifold and get a better fit.  I have only seen pics of the 1.9td
so don't really know if it's just the size of the turbo or if it's
the position.

JT
Idle Speculator

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com]On Behalf
Of Michael Snow
Sent: Tuesday, July 29, 2003 8:27 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: Turbo Diesel 1.9L mounting in a Westy

If you mount the 1.9TD in the same position as the stock 1.6D, it will
interfere with the engine lid.  The stock 1.6TD sold in Europe is
mounted in the 50 degree position, so the VW engineers must have thought
that oil drainage from the turbo would be adequate.  The turbocharger on
the 1.9TD is mounted in a different position, at least on the AAZ
engine.  This may or may not have a measurable effect on engine life.
Many 1.9TD owners have installed their engines in the 50 degree
position.  Despite much speculation about the issue, I have not heard a
single report of turbocharger failure attributed to doing it this way.

Mike Snow
1982 Westfalia diesel

Wengraf, John wrote:
>>I've heard various accounts about installing a new 1.9L diesel in a
vanagon.
>>
>>Can the enegine be mounted at 50 degrees and have no impairment on the
rear deck?
>>
>>Does mounting it in this way have any implication on reliability?  I was
told that Overland will no longer sell the 50 degree kit because there is a
problem getting oil to the turbo  (?? or something like that) when it is
mounted that way.
>>
>>Any insight would be much appreciated
>>
>>John Wengraf