what to do to get reliable 200hp?

[Han Solo]

well im pretty sure if i just add a fan to an air2air intercooler, i think that should make me happy and it will still get me to the power goal i need... again there are too many differing opinions to try to decide between, ill just have to try each when the time comes

for now though, the question remains: how do i get to 200 hp?

specifically looking at the internal parts of the engine... because im rebuilding the engine and just want to have a solid base to work with. i mean i dont want to have to go back in and add forged pistons when i find out they cant handle the boost or that i dont even have enough compression to get the motor going. if the other, more accessible items need to be worked on i can address them later, but id like to know about the internals please.  

my questions again are simply: is my setup good in the core area? or is there something else i need to look at? and is there anything else i could do? (keep in mind its a DD)

thanks for all the responses and hope everyones new years was full of good times

[vanagonturbo]

do you have a TD engine to start with? If so great! Either way, balance the entire rotating assembly and ceramic coat the pistons. The rods should be able to take 200hp.

you are thinking gasser when you mention forged pistons. AFAIK noone makes forged pistons for the IDI. Oil squirters and ceramic coating should take car of what you need for the bottom end.

Port match the head to the gaskets. This will help flow into the engine and into the turbo.

If you have a hydraulic engine, get an AAZ head. I dont think you will be able to reliably reach 200hp without it. If you cant afford that, then at least get some bigger valves in there. I have even heard of people getting SS valves from another application and cutting them to fit. This mostly applies to the intake valves. Audi 5ktd valves come to mind, but I am not for sure on that.

[Han Solo]

thats pretty much what i had in mind, i dont have a 1.6td though. :? i was going to machine in oil squirter's to make up for it.

and i was planing on the 1.9 head just didnt know if it bolts right up or not?

and how would doing that affect the engine, like does the compression change or anything? (this is kinda where ive found it hard to find information, i know its been done, but by people alot more skilled and knowledgeable than myself)

[vanagonturbo]

Well, the AAZ head has slightly lower compression due to the larger precups.

The next task you will have to deal with is the gasket/oil return. There is an extra one between #1 and #2 injector on the AAZ head. This will need to be plugged in order to use that head. The gasket that should be used is the AAZ gasket. but then again, you run into the extra oil return. I currently have the AAZ gasket on my mechanical 1.6 engine. I dont know how long my idea will last so I would like to reserve my trick until I know it will last a while. I currently have about 3k on the idea that I used for the gasket.

The AAZ head will require longer AAZ only head bolts. These are 12mm in diameter. If you have an 11mm block, your options are to drill and tap the block or get a kit from ARP that allows 12mm head with 11mm block.

I personally have an 11mm block but also have some 12mm blocks lying around. I will most likely be building one of the 12mm blocks for the AAZ head. I was going to put the AAZ head on the 1.6 block a few weeks ago until I found out the block in the car had 11mm bolts. And the head is cracked and has been welded on the 1.6. I figure that if I run into a problem with the 1.6 at least I can know what I did wrong and make it right for the build of the AAZ 1.6

machinig the oil squirters is a good idea. I dont know if anyone has had success with this though. still get the pistons ceramic coated. its a good precaution.

[Han Solo]

http://www.fastvws.com/acatalog/FASTADDICTION_com_Clutch___Transmission_Parts_9.html

should i get the:

Rapid Performance Sport Clutch Kit

Limited Slip Upgrade Kit

and the Techtonics Deluxe Short Shift Kit

anyone have experience with these types of products? i figure they will be able to take the power im attempting to put down?

and thanks again for all the helpful advice everyone

[jtanguay]

wait a minute... you don't have a TD?  and you want 200 hp?  :shock:

are you trying to kill the engine? hehe... yea you need a huge exhaust, 3"... huge intercooler... EGT gauge (try to keep below 1300 or so) and a really good pump.

why don't you firstly take a look at andy2's thread.  compound turbo's.  he slightly bent his rods so he went to PD100 rods which were bolt ons (for a 1.9 AAZ)

the 1.9 AAZ head will be good for the power... the lowered CR will help put less stress on the engine and maybe keep the rods from bending, but your cold starting will be pretty rough.

[Han Solo]

well like i said... i was going to get oil squirter's machined in would that not do the trick?

and will the compression still be an issue if i lighten all the spinning mass? or how can i get the compression to where it needs to be?

[vanagonturbo]

well you are going to need a turbo for sure if thats what you intend. no way in Hell are you going to get 200hp out of an NA diesel.

[jtanguay]

well like i said... i was going to get oil squirter's machined in would that not do the trick?

and will the compression still be an issue if i lighten all the spinning mass? or how can i get the compression to where it needs to be?

like i said... you only need the high compression ratio for cold starting.  200 hp should be for a 'racing' 1.6 diesel engine.  if you want it as your daily, i can't see it lasting that long...

so you might need to plug it in to have good starts, but it should go like stink if you build it right.

[vanagonturbo]

200hp should be acheivable (sp?) for a DD if its done right. A turbo is a must and a stock turbo will not work out so well. I think its all in the setup.

I see no reason why a 1.6l TD, fully built can not get to 200hp reliably. By reliably, I mean 60k miles or so with out needing major internal work.