1.6d to a 1.9d non turbo

Post by **SplendiferousII** » 16 Mar 2008, 12:57

Hi guys

I have just bought a 1.9 engine on ebay and plan to fit it inmy 1.6na diesel. Will it go straight in with just the obvious swap overs or do i need to do anything to the pump?

best i can do is this ebay link - Hope it works.

Yes it is a 1.9 was posted as a 1.6 by mistake.

http://cgi.ebay.co.uk/ws/eBayISAPI.dll? ... PIC&ih=015[/img]

Post by **Kermit** » 16 Mar 2008, 17:56

Ahh Ha.. I was going to bid on the very same engine just as a spare, but did not bother in the end as I have already spend £100's on it already this month....

You may have to do some fine tuning to the injection pump, it may have an immobiliser on it, which you literally have to take a chisel too to expose the solenoid valve underneath.

This solenoid is the only one you require, you can discard all the other cables, do a search on here and it has been asked before, this problem bogged me and weaselchin down for ages.

Also you may have to alter the accelerator lever as it sits a bit higher up, I manged to use the lever off the 1.6 pump and modify it so it just sits below the engine cover.

Kerr

Post by **SplendiferousII** » 16 Mar 2008, 19:16

Cheers Kermit. And many thanks for NOT bidding on it. I think I got a bit of a bargain at £41. And I desperatly need it my 1.6 is using more oil than fuel. The motor is actually very very good (my 1.6) its just hat I cut corners when I cooked it a while back and didnt bother with replacing the valve guide seals when I did the head - they are still on the shelf in the garage - opps.

I'll keep it as a spare.

I like your style with regards to hammer and Chissel on the Fuel pump. can you clarify that a little? Dont want to beat the wrong bit to death.

Is it a good upgrade and while I notice the 28% power gain?

1.6d = 50bhp 1.9d = 64bhp - thats what I found on tinternet anyway.

I dont want to go fast but I would like to be beating the trucks on the flat.

Post by **Kermit** » 16 Mar 2008, 20:06

Yes if the engine is sound then you do indeed have a bargin for £41, I emailed the guy and asked for the engine code and mileage but did not get a satisfactory reply ... but for £41 the pump is worth that as a spare!

Regarding the immobiliser, there is a black plastic section at the back of the pump, like I said take a chisel to it .. this will expose two screws which you can then unscrew to remove it further with mole grips, dont be shy it takes some force but bear in mind underneath all the plastic there is a fuel cut-off solenoid, just wire this up to your existing cable.

I will look later or tomorrow, but I may have been sad enough too have taken some photo's of me doing this when I did the conversion a while back.

Other things you may wish to condsider while the engine is out is changing the crankshaft seals etc, easy enough and a kit is available from GSF. also looking at the ebay pic, it looks a bit 'weathered' so change the timing belt and tensioner.

If you need to borrow an engine stand, lift or any other tools your most welcome .... but I want em back !!!

Any other issues, just ask

Kerr

Post by **SplendiferousII** » 16 Mar 2008, 20:16

Many thanks for the offer of the tools. I have everything I need I think. and a Forklift to lift the motor out.

I already intended to replace the crank seals, cam belt, tensioner and anything else I can think of.

Please do look for photo's as it will save me heart ache.

Regards

Splen

Post by **Kermit** » 16 Mar 2008, 20:40

I thought I had an above average selection of tools ... but forklift ain't one of them!!

Yep, ok will have a look tomorrow morn for pics of the pump, but basically its the same as your 1.6 pump now, without the plastic bits on the end.

Regarding power increase, I cannot really comment as I bought my van as a wreck and changed the engine before using it properly, I am using a 1.6 Aircooled DH box and use 16" Merc ML alloys, its by no means breathtaking but will do 80+ @ reasonable revs on the motorway. I am sure you will be more than happy with the conversion ..

Kerr

Post by **ringo** » 16 Mar 2008, 21:30

Kermit wrote:I am using a 1.6 Aircooled DH box and use 16" Merc ML alloys, its by no means breathtaking but will do 80+ @ reasonable revs on the motorway. I am sure you will be more than happy with the conversion ..

Kerr

Sweet jesus - that DH box must make a huge difference - mine will do 70 max. Maybe its the 16" rims?

Got me thinking now...

Ringo

Post by **SplendiferousII** » 16 Mar 2008, 21:52

Now thats interesting. as my 1.6 will pull 80 down hill with the wind behind it with ease. probably 90 if I had the balls. Flat out in third is 56mph (speedo reading so allow for error)

Post by **Kermit** » 16 Mar 2008, 22:10

What box are you using?

I am running 16" rims + the standard ML 225/16/75 tyres, which are a 'nice' (tight) fit in the arches and running gear with spacers ....There is a calculator flying around somewhere which works out the ratio/speed..

Its common to use the 2.0Ltr DK box (stronger/better ratio's), which I bought off a guy on the JK forum last year, unfortunatly he forgot to mention the 4th gear never worked .. fitting the ML's counter-acted the ratio difference on the DH.

I have never run the van on the standard diesel boxes, so again cannot comment.

Kerr

Post by **Kermit** » 17 Mar 2008, 09:17

The picture below points to the immobilizer that needs to be removed (assuming you have this on your pump).

[IMG:534:800]http://i2.photobucket.com/albums/y7/kerr888/IYPUMP9.jpg[/img]

The two holes in the back of the immobilizer are the security screws, you could try and drill them out first, if that fails take a chisel to it so you can get a grip on to them to unscrew.

Kerr

Post by **windysurfer** » 17 Mar 2008, 13:01

there's a calc here

http://www.partsemporium.co.uk/rpm%20&% ... ulator.htm

Kermit from what the calc tells me you will be doing 4246 RPM at 80mph

Post by **Kermit** » 17 Mar 2008, 13:41

I think the calc I used was this one:

http://www.miata.net/garage/tirecalc.html

Which tells me I am going 17.5% faster than indicated, so 70Mph would be 82MPh. - so does 4246 RPM sound about right?

The van is currently off the road and I have since bought a sat nav so I will go for a run in the next few weeks and will be able to tell exactly what she is doing from the speed indication on the sat nav.

Obviously I have no intension of breaking the 70mph speed limit, so all the above is purely theoretical ....

Kerr

Post by **SplendiferousII** » 17 Mar 2008, 18:14

Just done a quick estimation of crusing speed gain fitting the 1.9 engine.

Current level road crusing velocity = 55mph
Current produced HP = 50

New Hp = 64

55 squared = 3025. Divide by 50 = 60.5 Multiply by 64 = 3872 and the result is the square root.

New crusing speed = 62.2mph.

Quite acceptable.

Ok quite a basic calc but probably pretty accurate.

Post by **SplendiferousII** » 20 Mar 2008, 07:35

I collected the engine last night and can confirm that it is indeed a 1.9d - its cast into the back of the block !

It appears to be identical to the unit in your photo Kermit, so expect a few questions form me over the next few weeks - I hope thats A OK?

A couple of quick questions for now.

Do these engines have problems with the bottom pulley?

Did you use the newer style fan belt and pulleys or use the old system fitted to the original 1.6d engine?

Thats all for now.

Post by **ringo** » 20 Mar 2008, 08:12

SplendiferousII wrote:I collected the engine last night and can confirm that it is indeed a 1.9d - its cast into the back of the block !

It appears to be identical to the unit in your photo Kermit, so expect a few questions form me over the next few weeks - I hope thats A OK?

A couple of quick questions for now.

Do these engines have problems with the bottom pulley?

Did you use the newer style fan belt and pulleys or use the old system fitted to the original 1.6d engine?

Thats all for now.

Dont know about the pulley - not heard of any problems.

I used the new fanbelt - which meant i had to use the "proper" alternator that was fitted to the 1Y.

I must say, taking off the fanbelt is very easy with the spring loaded alternator...

Regards

Ringo