HOW TO make an VW M-TDI engine run with a VW 1.6L injection pump!

Olly explores in terrifying detail how to get the VW 1.6L injection pump to mount on (a 20 year newer) 1.9L TDI ALH engine. Watch if you dare lol. Injector lines, pump heads, mounting brackets, pulleys, & engine mounts :D
Cheers,
O

[@chrishervol3311]

thats awesome, everyone always said you couldn't use the 1.6 pump but here we are lol. i hope it works out well, may have to do this in the future.

[@OliverFetter]

Thanks!! Yeah I'm stoked it mounts up ok. I figured the upgraded internals will do the job 👍

[@TDISwap]

I will say that in my 14 years of learning about these motors, I can't recall an 1.6 pump working well on a TDI. I know that most recently someone told me that they did, but couldn't provide video proof. The pressures are vastly different (although you do address it in your video). Hopefully you can show us old fogies that it does work. That'll open up the options for everyone else. I bet you'll be limited in power due to pressure and she will smoke pretty darn good as well. If you need a 1.9 mTDI pump I have an acquaintance that imports them from Brazil (built by a friend) with 12MM pump heads that rev to 5K and are capable of 250-300 BHP. They are 1K USD shipped though. So not too cheap. Best of luck.

[@OliverFetter]

Re:pump, that's dank! I'll keep that in mind. Well see how it goes! This is certainly an experiment and if nothing more, a progression. It seems to me injection pressure should be fine (if not the same) since I'll be plucking the 11mm head out of the TDI pump. Certainly where it'll be lacking is in timing advance. To call it a 1.6 pump would be immaculate at this point though, it really is a Frankenstein of both with really just the 1.6 lift pump & drive shaft. Cheers 🍺

[@TDISwap]

@@OliverFetter I thought about it more today and was wondering what the popping pressure is on the 1.6 compared to the 1.9 injectors. I know the 1.9 had dual stage injectors, but don't know on the 1.6. Might be good to investigate.

[@OliverFetter]

For sure. 1.6 TD is 155 bar (single) looks like 1.9 is more like 230/310 (dual)

[@TDISwap]

@@OliverFetter just saw it's 155 bar for the turbo 1.6 and 220-230 bar for first stage and 300+ bar for second. You're going to have a bad time I think. Hopefully not though.

[@OliverFetter]

What do you think is specifically going to be a problem? I could see the input shaft potentially being too weak, other than that, it'll all be 1.9 parts anyways.

[@vwfatmobile3275]

Great info covering all the hurdles to putting a 1.6 pump on a TDI. Following for sure. When you remove the pump head's big center plug. You need to get a new one. The metal ring is a one-time-use seal that gets squashed on install. According to my local bosch service center, pump rebuilder, it can effect start of injection.. I've always heard the delivery valves on the TDI pump are for 2-stage injectors,.. like the injectors on the TDI. Great job. I'm trying the same thing with an AHU TDI engine. I heard it was easier to swap into a MK1 engine bay.

[@stevenharpervw]

Really enjoying your videos very informative. Will you also ad in what parts cars to get the parts from

[@OliverFetter]

Thanks! Hmm I don't really know. I think ALH is 2000-2004 golfs & Jettas? But you'd be best off looking it up 👍

[@Mikefngarage]

you just need to drill a piece of aluminum to the correct size of the 1.6 pump then put it in a lathe and trim it down to the 1.9 pump. Then put it in the hole and tig weld it in place. This will prevent the spacer from vibrating loose....Remember it is diesel. it will do that. I have often wondered about this sort of thing. I could have bought a ALH from pick a part a few weeks ago from a car with probably a bad trans. Was considering using a 97 mtdi pump. But also AAZ. I have a few 1.6 pumps that could be modified. Yea I also figured that the rotors and high pressure units would fit from later models. VW and bosch Seem to like to modify existing designs rather than come up with new ones.

[@OliverFetter]

I think a 3d printed spacer will do the trick. I don't have a lathe so 💁 owell. Definitely will need to be positively held into place I agree. You don't need to remind me my teeth rattle every time I start it 😂😂😂. Spot on with the Bosch modifying vs new. All parts fit everything almost.

[@user-rb2mf3hj3e]

Thanks for the investigative work Ollie. Could you use a mk1 Gas engine mount? would it bolt up? Or maybe just buy (the horror!!!😬) a mount from S&P. Just spitballing here. Again, thanks for providing the research.

[@OliverFetter]

😂😂😂 yeahhh honestly for the $ it might just be worth buying the mount lmao. Thanks for the comment!

[@samsimone3255]

Hey could you do a quick KZbin short on the oil cooler your running on your car now. just finishing up my 1.6tdi don’t really want to run the old oil cooler!

[@OliverFetter]

I'd be happy to. Check this video out for starters & let me know if there are any holes. I'll be at my shop later today. kzbin.info/www/bejne/npm4ZK17prOfoKMsi=tdbfJ-6H238PEBuc

[@stixstix212]

I just left 4 holes on my engine mount and cut the ring right off. Then it bolts right to the engine. All four holes should be there but hard to see or under something that you can pull off.

[@OliverFetter]

Thanks!

[@tomaspinto7079]

Is the 1.6 pump that you have (mods included) similar too the 1.9 td pump? (AAZ engine code if im not wrong) and doesn't it need a lot more pressure for direct injection ? I love your chanel mate please keep it running. As you always say cheers🍺🍺

[@OliverFetter]

I'm not very familiar with the AAZ pumps but id imagine it is quite similar. Yes! The 1.6 is 155 bar pop pressure and the 1.9 is 230/310 bar 💁 not sure what to predict there. On the one hand it's quite a bit more pressure, on the other hand I'm using tdi parts to modify the pump, so I can't see why it wouldn't work. It seems to come down to the input shafts if something had to break BUT we'll just see 😎 gotta test it out before caving to speculation!! Cheers haha 🍺🍺🍺

[@dylanromine4101]

You can put a 1.6 pump on a 1.9 aah, ahu, or 1z because they are based on the 1.6

[@OliverFetter]

Hmm. Do you know what makes it particularly compatible?

[@dylanromine4101]

@@OliverFetter the mounting plate is similar to 1.6 on those engines

[@bigdirtyspeedsrt]

sick

[@user-px9lc9rr4s]

Will you still need the ECU to control the injector and other sensors and whatnot

[@OliverFetter]

That's the cool part... no! The injection pump controls the injection timing, and it's all mechanical 👍

[@user-px9lc9rr4s]

Ahhh cool

[@powerstrokemaintenance]

The impact adapter setup is ludicrous lol

[@OliverFetter]

I thought it was heinous enough to mention lol

[@user-iz8hn5oo7n]

It aint all that bad putting the 1.6 on the 1.9😂. I mean, i have done it with a 1.6td pump on my 1.9tdi AHU. The AHU and ALH are similar. But also i am running on p520's nozzles, which makes it alot more fun to drive. It doesnt smoke because i made adjustments by raising the star wheel and a little modification to the boost pin. It run pretty ok until i can manage to get another 1.9tdi pump. Top out about 85-90mph.

[@OliverFetter]

I know 😂😂 you'd think it was the end of the world the way people talk about it. That's cool! I think it's going to work pretty well since its just a 1.6 pump body with 1.9 internals 🍺🍺 cheers

[@gulfy09]

I've done the same thing 20 years ago it runs

[@greek750]

How to set the timing

[@OliverFetter]

If your wondering about 1.6 specifically - that can be found here: kzbin.info/www/bejne/g5yoeX-Nr7KEe5o

[@OliverFetter]

But for the 1.6/1.9 combo it will be kinda the same! It'll be all the usual 1.9 timing marks, then aligning the TDC mark on the pump pulley to the TDC mark on the 1.9 mounting bracket. Not too bad!

[@ChrisGR93_TxS]

oh god. You definitely will lose a lot of power with this fuel pump configuration. Tdi uses higher fuel pressure and the 1.6 pump is gonna underperform your tdi a LOT. (tdi injectors are rated to open and operate on higher pressure) I'd use the 038 pump and try to manually wire it.

[@OliverFetter]

I mean it's a 1.6 pump *body* but it (the actual pump I will put to work) uses an 11mm TDI pump head and TDI rotor. I see no reason why the pressure would be insufficient. Certainly there will be a lack of timing advance when compared to the electronic counterpart but it's literally the same parts otherwise 👍

[@antoineagius1181]

Hello, l'm sorry but on this one l don't agree , best power to modify the 1.9 one. Good luck

[@antoineagius1181]

For the front engine mount its good too use those two bolts, you need a plate cut to shape and modify the original mount to weld the new plate. Unless you have the 1.9 mount and you can use part of it too.