Not a straight diesel swop

Post by **futbus** » 30 Oct 2005, 08:51

I bought a 97 Polo diesel 1.9 engine (AEF) off ebay for a fairly cheap amount with 80k on the clock and copys of all the service history, so thought I had a good replacement for the 1.6 diesel in the panel which is knacked.

Started to strip polo lump down yesterday and removed 1.6 from van only to find a few differences which I thought I would share.

The polo has power steering, but removing it means replacing all the pulleys from the old engine and swopping the alternator which is a 90amp which was to be kept to run the van when putting a camper interior in.

The dipstick hole is on the wrong side, so will need tapping and plugging and a new hole drilled in the other side.

The pump has alot of wires coming from it, two seperate ones appear to go to fuel cutoffs either side of the pump, three wires go to the top where the accelerator linkage is, and two more disappear under the pump (hope to find out where these go today).

So engine not going back in today, due to what I found. I can get around the steering pump and dipstick issue, but need advice on what all the wires off the pump do and which to connect my single original wire to?

I have taken some photos with my phone but not yet worked out how to put onto computer to show you what I`m talking about.

I`ll keep you informed on how this goes during the next few days.

Post by TD » 31 Oct 2005, 20:23

would it have been easier to get a VEGE replacement for your van?, just slip it in and off you go with 12 months guarantee?
Let us know. Trouble with these 'replacement' engines is that they assume you have a full worksop with fabrication processess ,all to hand and of course acess to whatever conversion accessories you need.
VW had these when they slotted engines into whatever shells came along the production line.

Post by **Simon Baxter** » 31 Oct 2005, 21:29

After a quick scan of some stuff here seems your engine has a glow control unit and a load of sensors on the pump.
Hope you got all the bits.
Unsure about dipstick though still.

Post by **futbus** » 02 Nov 2005, 21:37

No just got the engine, so will I have to change the pump if so to which one? anyone got a standard 1900 pump non turbo pump? Any ideas if I can keep the original.

All suggestions welcome

Post by **syncroand101** » 02 Nov 2005, 21:43

If you want to text me the pics, I'll stick 'em up for ya?

07966 47 10 99

Post by **futbus** » 02 Nov 2005, 22:08

Photos sent, hope there ok.

Dave

Post by **syncroand101** » 02 Nov 2005, 22:20

et voila:

I See what you mean about the dipstick!

Post by **airhead** » 03 Nov 2005, 17:29

I recommend getting a technical manual for that polo and findoing out what the wires do from that.

Post by **futbus** » 03 Nov 2005, 18:50

Been thinking that if I can find rest of the bits, may put the 1.9td in the hole instead. I have an engine and sump, just need hoses and wiring, and a decent turbo and manifold.