Did a bit of reading tonight since I've been planning an engine conversion for god knows how long, I stumbled accross a topic on some other website, I can't find the link, but they were on about solving some sensor problem on a 1.9 TDI 6n2 estate.

I thought hmmm, they made a 1.9 TDI 6n2? I went on eBay and found this:

http://www.ebay.co.uk/itm/Volkswagen-Polo-1-9TDI-90-bhp-2000-S-Estate-Diesel-YARD-CLEARANCE-750-/261556605964?pt=Automobiles_UK&hash=item3ce5fd140c

I've seen the estate a few times in real life, it looks like a cross between a 6n and a 6n2, but a bit of research suggests that car has a 90hp non-PD engine, and it is turbocharged. I was wondering if that engine can be transplanted into my 1.4 TDI Polo, if I bought something like that to use as a donor car, reckon the chassis on that is the same as the rest of the 6n2 Polos?

I could throw a PD cylinder head and turbo kit on it later, lol.

I just didn't know the 1.9 TDI was fitted to any kind of 6n2, is this a bit of hope for making my engine conversion slightly easier?

Cheers!

The Estates are. 6kv chassis where as polos our 6n. Meaning the estates is based on a seat Ibiza same as the seat corbada inca van caddy van. Which u may know as came with a variety of engine the Ibiza having a 1.8t fitted as factor. These cars support the big block the polos don't. If you won't a pd engine you are option is 1.4tdi from a 6n2 can be tuned and will reach 100bhp easy. If your set on a bigger engine look at some of the 1.8t build threads on here same amount of work will be needed to fit one.

The engine in my Polo is already a 1.4 TDI PD which is already remapped. I figured keeping the car a diesel would be easier, the work involved on fitting say a 1.9 TDI PD from a Skoda Fabia, or a Golf or whatever, would be custom made driveshafts, welding a bracket from the crossmembers to support the front of the engine, modifying the subframe to include mounts for the rear of the engine, presumably fabricate new gearbox mounts. I looked at a design where the guy had cut into the front crash bar and bolted a front mounted intercooler to it going underneith.

To my knowledge the 1.4 TDI is a shortened 1.9 TDI engine, in that there is one less cylinder, and presumably the crankshaft/camshaft have different configurations for different firing orders, dimension wise would a 1.9 only be a bit wider than the 1.4, just I've heard a lot of people say the 1.9 block is taller. The bore/stroke diameter of the pistons in both engines is exactly the same, I can't see why it would be nessicary to be taller.

There's obviously pedal box and wiring issues to sort out, but I can just see the physical fitting of the engine being the most challenging part. I know it's not impossible because I've seen many successful build threads with 1.8 turbo engines, and pretty sure a couple with the 1.9 engine.

EDIT: I'm aiming for around 200hp which I know a 1.9 is pretty capable of, the 1.9 engine is gonna have a bit (80kg+?) extra weight to it so keeping it stock I can't visualise it being amazingly faster. I can probably find the money for a nice bit of custom tuning later on, but the engine would go in mechanically stock, with a new clutch, serviced up, Awesome GTI remap etc.

Edited 1 September, 201412 yr by Aled Owen

I said look at 1.8 t to see what work is involved same block size, the pd engine 1.4 is just a cylinder missing the extra cylinder will mean it touches thee chassis leg it's huge work for little gain I would look a tuning the 1.4 for the money u will put into ten converison u will easily be able to tune the 1.4 to some decent power figures. Straight threw pipe egr delete dpf/cat delete head work dark side developments had a few cams re ground maybe shot them a message 150-170 would be ball park with a decent turbo set up again dark side could make a manifold to fit one of there garret turbos.

You can fit the 1.9 injectors/intercooler/turbo etc to get around 140bhp... There's a couple that have done that now. And if you add on straight through and egr delete etc as Matty said you should see some more

What about the cars that were fitted with the 1.9SDI from the factory?

^ There completey different block ^

^ There completey different block ^

Well sod me, didn't know that

Thread resurrection! xD

I'm working on a Polo GTI at the moment, the engine bay's getting stripped out and an AUQ (180hp) 20vt engine is being prepared to go in at this current moment in time (that's reconditioning ancillaries, head gasket, oil pump, shallow sump kit, etc) and I'll be ordering a Portamig 215 MIG welder next week, which is probably gonna help me do all the engine bay fabrication. I'm pretty competent at MIG welding, especially considering it's the easiest welding procedure around...

I've still got my 1.4 TDI Polo which I use as a daily car. Plus 1.9 PD TDI engines aren't expensive, so I thought I might try and use the experience from doing the 20vt conversion to convert my 1.4 to a 1.9 TDI, so at stage 1 it'll be running 170hp and 300lb/ft torque, which is 100lb/ft more than what it's at atm, and about 80hp more too. And that's before I get serious with the tuning! xD

I could buy an engine and gearbox from a Golf GT TDI, they seem pretty cheap these days... The fuel lines and tank are already diesel, the fuelling system between 1.4/1.9 seems/is the same. Apparently 1.9TDI/20vt engines mount the same and the dimensions are roughly the same, so the fabrication of the mounts and the mods inside the bay would be the same as the 20vt conversion. The exhaust manifold, like the 1.9/20vt, is rammed at the back of the bay, so the exhaust system might not be so hard to do, it'll be a full straight pipe, like my car almost is at the moment (just the backbox on atm).

Suspension is Weitec Hicon GT coilovers, they can stay on, I'll just need to fit Powerflex bushes to the rest of the car, that's a must-do thing. The driveshafts are a no brainer, make temporary ones then get some custom made. I can use the same brake setup as the 20vt system, which is 4 piston Hi-Spec calipers over drilled MTEC discs and Ferodo pads, with Goodridge braided hoses.

The thing which may make this conversion even easier than the 20vt is the wiring. The big question today is d'you reckon the wiring loom on the 1.4 TDI and 1.9 TDI is at least similar enough to not need a lot of modification, considering the engines are so similar (apart from obviously one being 4 cylinder). Generally speaking everything is in the same place, and they're both PD engines, it shouldn't be particularly difficult to do the wiring conversion? I could do with robbing some wiring diagrams from somewhere, for starters I don't have any kind of workshop manual for the 1.4, would anybody be able to shed some light on this?

Cheers

Aled

You are doing exactly what I am doing mate.

I am going to take an ARL engine out of a golf and dump it in the polo. Also considered the BKD engine but that is a different story. Have a search on the net, can't remember the site but there is a guy who tuned his to something like 320bhp and insane torque figures. The thing was an animal. Whilst still maintaining the MPG you can't beat a diesel for a daily beast.

Anyway, moving onto your question. I personally can not help you wiith the query. However, speak to this chap damians1992. He is a member on here who done a 1.9 TDi conversion. Can't remember out of what car or what the engine code was. But he would be a good place to start with any and all questions to do with this conversion. There was also a guy over on e38 that done an arl conversion in a 6n2 some 4-5years ago now I think. It was featured in PVW. I did ttry contacting him, but for lack of a better word the guy was a c**t. Wanted to sell his advice to me, fucking goon! What has happened to communal spirit these days. Anywho, get in touch with that member on here and he has been pretty helpful to me whenever I have asked for it.