My 1.6 > 1.9 Coversion So Far...

[matty_gti 20]

hi all, ive allready askd a few randon questions about my rebuild and so far i think its goin rather well so instead of doin lots of little posts, i thought id just to a big one with lots of questions and pictures!.

 

A few months ago i blew my engine mounts on the block and head sky hi!, the ally surrounding the bolts simply exploded after hitting a pot hole casuing the engine to drop down around 3 inches, smashing my drivers drive shaft and fookin up my gearbox bearings:(. after my dad towed me home i felt like crying, simply because i spent a whole year and two months spending time and effort and alot of money turning this:

 

http://i81.photobucket.com/albums/j218/matty_gti/76_1_b.jpg

http://i81.photobucket.com/albums/j218/matty_gti/75_1_b.jpg

 

Into:

 

http://i81.photobucket.com/albums/j218/matty_gti/205GTi.jpg

http://i81.photobucket.com/albums/j218/mat...ti/DSC00135.jpg

 

To get to that i did need to pick at another 1.6 which i broke up:

 

http://i81.photobucket.com/albums/j218/mat...ti/DSC00127.jpg

 

After my GTi broke, i bought my 3rd one, you can see my car im rebuilding behind it:

 

http://i81.photobucket.com/albums/j218/mat...ti/DSC00385.jpg

 

But then i sold my 3rd GTi and scrapd the 2nd one and now im back to my first car which i love dearly :

 

http://i81.photobucket.com/albums/j218/mat...ti/DSC00043.jpg

 

So thats the story so far. A few months ago i started to take out my engine and then my plans for it started to come together, i wanted every single thing either new or refurbd. i went for lightend and balanced, rods, pistons and flywheel. All new bearings and crank reground. New rings and liners honed. fully rebuilt and skimmed head...basically everything....even the nuts and bolts....the plan is eventually i want TB's

 

After taking my engine out i thought when i put it back in i want it dead clean, even tho i know it wont stay like that for long so here are my nice 'n' clean pics

 

Before:

http://i81.photobucket.com/albums/j218/mat...ti/DSC00263.jpg

 

After: Painted block and head then started on the bottom end...

http://i81.photobucket.com/albums/j218/mat...ti/DSC00283.jpg http://i81.photobucket.com/albums/j218/mat...ti/DSC00334.jpg

http://i81.photobucket.com/albums/j218/mat...ti/DSC00294.jpg

http://i81.photobucket.com/albums/j218/mat...i/DSC00264d.jpg

 

So theres the progress so far....tonight ill be putting on the head so pics will follow shortly.

 

Now for my q's.

 

1) Because im goin from 1.6 > 1.9 i have a sump spacer, do i need a oil pump spacer aswell?

 

2) Can i use my 1.6 dist or is a 1.9 dist recommended?

 

3) Where does the wire with the multi plug on the dist go/connect to?.

 

Hope u like my looooonnnng post, sorry if its boring

[Atari Boy 11]

Sorry, I can't help with the questions but you have been really busy.

It will interesting to see how you get on as I would like to go from a 1.6 to a 1.9 in the future.

Good luck

[pug309twin40s 1]

So theres the progress so far....tonight ill be putting on the head so pics will follow shortly.

 

Now for my q's.

 

1) Because im goin from 1.6 > 1.9 i have a sump spacer, do i need a oil pump spacer aswell?

 

2) Can i use my 1.6 dist or is a 1.9 dist recommended?

 

3) Where does the wire with the multi plug on the dist go/connect to?.

 

Hope u like my looooonnnng post, sorry if its boring

 

 

1. Oil pump is the same on both engines. no spacers on them

 

2. You will need to use 1.9 dizzy, 1.9 ecu, 1.9 afm, 1.9 injectors.

 

3. wire that comes of the dizzy connects to the wire with pug on it from the ignition module

[matty_gti 20]

After getting everything ready so i can finaly put the head on, when it came to torquing the bolts 300 degrees one of the bolts stripped the god damm thread out the block which has really annoyd me after spending alot of time preparing the block and painting it .

I allmost feel like giving up.

[Guest BrainFluid]

Bummer dude. Dont give up! Take a look at Puma Racing's web site, he has jotted down a better method for headbolt tightening to try and negate this from happening on the next block.

 

EDIT: Would you trust a helicoil or retapping? I'm sure this has been covered a couple of times on here if you want to know more.

Edited December 22, 2006 by BrainFluid

[steve@cornwall 100]

Bummer dude. Dont give up! Take a look at Puma Racing's web site, he has jotted down a better method for headbolt tightening to try and negate this from happening on the next block.

 

EDIT: Would you trust a helicoil or retapping? I'm sure this has been covered a couple of times on here if you want to know more.

 

I've seen blocks where the rear headbolts have been retained with a nut on the protruding threads-ran fine.

Obviously not the best solution, especially on an otherwise meticulous rebuild, but as a budget, keep it running economically solution are there any issues with this method?

[matty_gti 20]

I've seen blocks where the rear headbolts have been retained with a nut on the protruding threads-ran fine.

Obviously not the best solution, especially on an otherwise meticulous rebuild, but as a budget, keep it running economically solution are there any issues with this method?

 

I either had the option of a helicoil (my boss at work told me to do), or retapping or using a nut at the bottom of the bolt, but seeing as its gonna be more than a standerd engine and not just a 'falling apart runaround' i need to do it properly seeing as ive got the chance to. So my plan is to just replace the block seeing as its only got the crank, pistons and liners and water pump in, i know ill have to measure how much the liners protrude from the block and do all the prep work again but itll stop me from worrying when im putting my foot down.....

 

Thanks for the input guys...

[matty_gti 20]

well...after fitting my 1.1 with a new cambelt amoungst other things it was time to turn my attention to the car in need. My fecked block is still sitting untouched in the garage however i did go out and buy a 2nd hand engine+g.box on ebay for 100 pound notes!...bargain!....so the progress so far.........

 

The new engine...

http://i81.photobucket.com/albums/j218/mat...ti/DSC00609.jpg

 

My engine bay was filthy so out came the white spirit and a rag!!

 

The engine going in...

http://i81.photobucket.com/albums/j218/mat...ti/DSC00623.jpg

http://i81.photobucket.com/albums/j218/mat...ti/DSC00611.jpg

 

And the engine in....

http://i81.photobucket.com/albums/j218/mat...ti/DSC00626.jpg

 

 

Shortly after fitting the new engine i went to see another 1.6 GTi i found on ebay.....and i just couldnt help my self, i ended up buying it ...

 

http://i81.photobucket.com/albums/j218/matty_gti/205GTi1.jpg

http://i81.photobucket.com/albums/j218/mat...i/205GTi1-1.jpg

 

My mum wasent impressed coming back from collecting my bro from school seeing a 3rd pug on the drive!

[Dazza 4]

Nice little 1.6 that Matty , dont worry your mum will still iron your cloths and love you plenty ..

[matty_gti 20]

Nice little 1.6 that Matty , dont worry your mum will still iron your cloths and love you plenty ..

 

lol, I hope so!. Allthough i do have a garage half filled with the 1.9 engine im building, bits all over the place....a shed filled with bits and a car-port filled with the old engine that came out!....and dont forget all the tools every where!

Edited March 13, 2007 by matty_gti

[matty_gti 20]

Right, yesterday i orderd my ali rad and will be arriving tomorrow so this morning ive just been 'adjusting' the rad cowling ready for it...

 

 

Ive also orderd a new standerd downpipe so hopefully ill fit both tomorrow.

Edited March 14, 2007 by matty_gti

[boldy205 74]

i like your style with the whole car buying!! i have plenty on ear bashing from my folks, got a 205 in the garage thats been there for months slowly modding it, a MK2 golf as a my 205 has been off the Rd so long a motor bike, half own a triumph 2000(that turned up on the drive while they were on holiday!!) and a work van!! HeHe!

that looks like one tidy 1.6 by the way!