Budget buildup

[smoken u]

Hello to every one, awesome site lots of good information.

Been into diesels for a while, helped my bud build up a dodge 2500 with cummins. Have owned a 1990 jeta 1.6 TD for about 1 year now. piped it, and K$N filter.

I just got a brand new new block for it (1.6 hydro) from work ( awesome deal ) am looking to build it up for more power, but am on a bit of a budget. about a grand. with a 1.9 IDI head on it, what would some cheap mods be to give me more power, I'm aiming for 150+

[burn_your_money]

look for 935racer's build thread for some inspiration

[flapjack]

here it is
http://vwdiesel.net/phpBB/viewtopic.php?t=11698

I'd get a junkyard intercooler and spend the whole grand on a giles pump

[subsonic]

Do you just have the block, or a doner engine as well?  Do you have a 1.9 head as well?  What kind of shape is it in?  If you picked up a block at work, I would assume you have access to parts?

If you have good parts you can swap into the block, or it is in fact a short block here is what I would do fo 1 grand.

1. Get the PP 3" down pipe, or hit up some members who might want to trade sell you there 2.5" so they could get a new 3"SS one.

2.  Go 3" all the way to the rear.

3. Get a stock vw t3.  Get a rebuild kit w/ 360 degree bearing upgrade, about 120 bucks. Rebuild it.  Look at porting the turbine- thats about 120 bucks.

4.  Gasket match the 1.9 intake and the stock 1.6td exhaust manifold.

5.  Shop hard for a good intercooler.  A bad intercooler is worse than no intercooler.  Plumb it in up front.

6.  Perform the fuel pump mods that are listed in the FAQ about making your 1.6 faster.

7.  new glow plugs and rebuild injectors.

That might take you over 1000.  Not sure.  Be frugal and shop hard, than you can drive hard

[oldskool rich]

most of the bits you need can be obtained from the scrap yard, my aaz is well over 150 bhp and it has cost me under £100 :shock:

just know what you are looking for and where to find it.

[smoken u]

just have the bare block, heads in good shape, new valves in it, have a friend who is sponsered to race, he can get it ported and polished for free.
at the moment I don't have a donor motor, but i'm going to the scrap yard tommorrow to see if I can get one.

[burn_your_money]

How's that saying go...

 speed, reliability, cheap. Pick two

I'd start with a boost gauge, oil pressure gauge and an EGT gauge

[smoken u]

already got the guages they are in the car now.

stock makes 12 psi

[MaxHedrm]

Cool ... I just need to add the EGT & Boost when I swap stuff out. Since I recently acquired a 1.6TD methinks I'll read through that thread too. I had been ignoring the TD stuff for the most part since my car was an NA.

[jtanguay]

get a big exhaust and a huge intercooler and run insane boost & fueling!!  :twisted:  keep an eye on oil level and smoke level.  the smoke with a larger exhaust system isn't as harmful as smoke with the dinky stock pee hole (no exaggeration!) sized system.

going that route should get you in the 150hp range with decent longevity.  things most likely needed to upgrade in the near future: clutch, new front tires  :twisted: possibly cv joints???  :lol: and a few motor mounts???  the passat mounts are pretty beefy and 'should' fit right in.

just make sure that you don't smoke too much for too long... short runs at pedal to the metal should be ok... 5th gear full pedal will make your egt's run wild!!!!!!!!!!!!!!!!!!!

BUT why do all this without an aircraft spruce gauge that costs around $80 bux??? it's just plain stupid if you ask me... it's like cheap insurance for your 'built-up' engine  :wink:

[smoken u]

what is the max safe EGT?

[jtanguay]

what is the max safe EGT?

general consensus here for a true TD engine is around 1600F although you wouldn't want to hold that for long... just small spurts?  then again others have held that temp & further without doing much (even any) damage.  again the large exhaust is really going to help keep those EGT's down.

[smoken u]

Thanks for the info. that's higher than a cummins is recommended (1500)

going to rotate boost pin today on jetta. see what happens :twisted:

[smoken u]

couldn't get top off pump, ran out of WD40, tried tapping them. still managed to get the max fuel adjust ment to turn though , put it in 1.5 turns.

[jimfoo]

Was the engine running while you adjusted it? if it wasn't, be prepared for a runaway engine as soon as you start it. You should normally adjust it a little at a time, watching the idle speed, turning down the idle screw and repeating until the idle won't go down any more, then adjusting it for the idle you want. 1.5 turns is quite a bit.