Club 80-90 Forums

I have the chance to get for free a 2006 1.9 TDI engine complete with ECU loom everything in fact, the question is how much of a pain is it  to fit into my 1989 1.6 TD type 3? I have access to a proper garage so in a way its easier than doing it at home on the drive.
Thanks in advance

Do you know what the type code is for the engine? There are known conversions for certain specific engine codes, but the amount of work that’s required depends on which type you’ve got.

Yes had a look and its BKC engine code, its just a thought due to the lack of power from my 1.6 TD original engine, if its going to be a real pain I will suffer the gathering pace rather than acceleration !

BKC is PD tdi engine. Not impossible to put in but it is not a straight forward swap.

So is their a thread anywhere that describes the pain of fitting the said engine?

An excellent engine the 1.9 pd tdi. My mk4 golf I bought as a cheapy last year has 165k on it and runs sweet and get 45-50mpg

Well today I was also offered the 1.9 mechanical injection TDI complete car good engine so I would again have everything I need, the specialist told me it would be a better option, just send off the ECU to have the immobilizer removed, again its a gizit so no cost to me.
I know it has less power but its an easy fit and will still make my camper go better

The 1.9 TDi's, both rotary pump, and PD, were excellent, robust, quite economical engines. The later rotary pump versions with the VNT turbos are preferred over the earlier wastegate ones. I have the 110hp AFN in my pickup and it reliably does 30mpg+.

 

So I fitted the AGR engine which was a pain it involved putting the sump lump off the JX onto the AGR sump also the electric throttle pedal. I have an oil leak problem from the rear main seal which I suspect is because I have to much oil in the engine anybody have any ideas how much oil it should hold? it seems to stop leaking just above the bottom of the dipstick! me being the dipstick in this case. Also my KKK 14 turbo which was new before I bought the van this year has a knackered wastegate due to never being adjusted up, the center screw was completely undone which explains the lack of performance from the JX engine. So I dont want to fit the turbo from the golf mk 4 as its knackered and it means lots of modding to the exhaust, and my original exhaust is new, so any ideas of a fix or where to get a wastegate from if the old one is to knackered, or if the whole turbo is knackered where to source a suitable replacement from

The AGR is a 90hp engine with a Bosch VP pump and a wastegate turbo. It is a Euro 2 engine, and was replaced by the 90hp ALH which is Euro 3 and has a VNT turbo.

If you've managed to fit the AGR engine at 55 degrees into a T3 and need a new turbo, Brickwerks do a custom turbo with a 'JX' style housing, intended to work with the previous generation 90hp wastegate TDI engines (1Z,AHU). This allows use of a T3 style exhaust system, and may work OK with the AGR. The AGR and AHU use the same injector nozzle so I suspect their ECU maps etc are quite similar.

PS. I just checked their webshop and couldn't see this turbo, so it may be a spacial order item, best to make contact and enquire if interested.

Thanks for your help I have sent an email to them and await their reply I am also trying to find an actuator as well

Normally a TDI turbo would be supplied with the actuator already attached and adjusted. The ECU controls the N75 valve to adjust the turbo wastegate actuator.

syncroandy wrote: ↑05 Oct 2020, 12:39 Normally a TDI turbo would be supplied with the actuator already attached and adjusted. The ECU controls the N75 valve to adjust the turbo wastegate actuator.

I am sticking with the KKK 14 turbo it was new a few thousand miles ago however as I said the wastegate actuator was never adjusted so it appears to have burnt out the valve!! I wont find out until I strip the turbo off whether the actual turbo is ok

So I drained the oil and refilled it with the correct quantity, removed dipstick and lengthened it so it went into the oil and gave a reading, this has stopped my oil leak also it has allowed me to drive the van. The upshot is that at the beginning it didnt boost at the end it was boosting mildly, the engine pulls better than the knackered JX it also slows down when releasing the accelerator, something that the JX didnt do due to lack of compression. So I have ordered the turbo gasket set and the boost bleed off hose and a boost controller, I have a pressure gauge at the garage so I can have a play also see if the turbo improves now the wastegate has been adjusted.
I have to say that the conversion wasnt hard just fiddly, not expensive probably 250 squids including the stuff I bought today, I fitted a clutch, spigot bearing, secondhand flywheel, secondhand but new exhaust pipe, welding sump and some oil, so I will run it a while and post the final results when the other stuff is fitted

So today I fitted tyres, I had on the beast 185 65 15s which were to small, after playing around at AP tyres we settled on 195 80 15c s they have upped the gearing by just over 6% on original sizes and 10.5 % over the ones that were on the van. I had to do something as 2 of the tyres had been run underinflated so had wear on the outside edges and I had a screw in another which had a slow leak, fingers crossed that the van needs nowt else this year that costs readies work I can do