1.6 to 1.9 conversion - nearly there!!!!!!

[Bobass]

Morning all
Looking for a bit of urgent advice if possible.
My mechanic has been slowly swapping my normally aspirated 1.6d to a a similar 1.9d from a Mark III Golf.
Progress has been good up to today:
A T25 1.6 sump has been fitted to the 1.9 - so it sits right in the T25, however, the new 1.6 oil pump fitted "gets in the way of the con rod at its lowest point" -- he says there may be scope for a bit of grinding!

Has anyone seen/overcome this problem before?

Thanks Bob

[HarryMann]

The problem is he's trying to use a new pump and suction pipe, you have to use the orignal suction pipe, filter screen, with the new pump body...

Sop hopefully you haven't chucked the old pump away!

[Bobass]

Cheers Harryman
I ran this past hime and he said the new pump came as a single module - so couldn't use other bits.
He says he's ground a small area off, which seems to have done the job - without affecting the pump in any way.

Thanks for the input

[HarryMann]

What was the new pump sold for, a JX or an AAZ/1Y with a normal sump.. hopefully not the latter!

I presume the oil pickup on the new one will lie flush with sump floor taking into account the 52 degree angle of the block Vs the sump bottom

Also, is he using the combined sump seal gasket/splash plate or just the plain gasket. If the former, then that too may need relieving to allow for the rod ends to miss it on one cylinder (I use that ''windage tray' myself , others prefer the simple gasket...

[andysimpson]

Wont make a difference if pump is for a JX or AAZ the important bit is to use origianl JX pick up and hope its a good one

[ringo]

Cheers Harryman
I ran this past hime and he said the new pump came as a single module - so couldn't use other bits.
He says he's ground a small area off, which seems to have done the job - without affecting the pump in any way.

Thanks for the input

I had to "clear" a pump that i bought from GSF - it was fine after that. I would suggest your mechanic has done the right thing - as long as the pump is intended for a JX (it wouldnt fit in the sump otherwise would it?).

Cheers

Ringo

[weldore]

What was the new pump sold for, a JX or an AAZ/1Y with a normal sump.. hopefully not the latter!

I presume the oil pickup on the new one will lie flush with sump floor taking into account the 52 degree angle of the block Vs the sump bottom

Also, is he using the combined sump seal gasket/splash plate or just the plain gasket. If the former, then that too may need relieving to allow for the rod ends to miss it on one cylinder (I use that ''windage tray' myself , others prefer the simple gasket...

did you manage to get the sump to bell housing bolts in ok or did you have to modify it slightly?
i used the windage tray but the 2 lower bolts were out of line..not much but enough to make me not put them in .in fear of cross threading

[HarryMann]

What do you mean by the two lower bolts ? You mean the two large longitudinal through bolts ?

All mine are in and I rate the windage tray as a worthwhile thing to fit, and yes, did need a small fragment cutting out with Gilbows

Sump fitting procedure

[weldore]

thanks for the procedure...will be taking the sump off soon to sort out my dipstick and will be looking back on this

[HarryMann]

Think this might have beeen a better link to clarify things...

1.9 pump pickup interference