Performance Ideas for a top end rebuild? - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• Performance Ideas for a top end rebuild? by chrisrandle1 on 21 Apr, 2008 01:05
• Hello; I am about to start a top end rebuild of a 1992 Jetta EcoDiesel.  I was interested in hearing some ideas on performance upgrades while the head is off.  The timing belt went so I have some valves to replace.  I will also be replacing the turbo.  I am interested in improving the stock 59 HP.
  
  Thanks a bunch
• #1 by truckinwagen on 21 Apr, 2008 01:33
• if you feel like living a little and taking some risks, port the head while it is off and the valves are out.
  better flow means better power.
• #2 by Rat407 on 21 Apr, 2008 01:45
• Major improvement would be to install a new 2.5 or 3 inch down pipe and exhaust all the way back. That really woke up my 91 ECO. Also a Giles pump  mode made a big difference as well.  
  
  I like my K14, just the right amount of boost when needed for a daily driver. What other turbo where you wanting to get?
• #3 by stewardc on 21 Apr, 2008 06:47
• Try one of the aftermarket camshafts that PP offers, port the head, Install ARP studs and a 1.9 metal head gasket.
• #4 by chrisrandle1 on 28 Apr, 2008 21:48
• Hello;
  Today I took the head off of my car and found that all but one of the valves had kissed the pistons when the timing belt broke.  There are also cracks between all of the cylinders along with cracks in all of the precups.  So now I am in the market for a clean complete head.
  
  I was looking at some of the posts about the 1.9 head on the 1.6 block, sounds interesting, I just don't seem to be able to find a complete beginning to end story on it.
  
  Anyone have a source for a complete head.  Maybe a 1.9 head if its not a nightmare.
  
  Thanks and any info would be great.
• #5 by Pat Dolan on 28 Apr, 2008 22:33
• You might also want to pull the pistons for a good look.  Often when the valves kiss, the crown of the piston distorts the ring grooves enough to seize the rings.
  
  In other words, you may be looking for an entire used engine.
• #6 by zukgod1 on 29 Apr, 2008 06:59
• Quote from: "chrisrandle1"

  Hello;
  Today I took the head off of my car and found that all but one of the valves had kissed the pistons when the timing belt broke.  There are also cracks between all of the cylinders along with cracks in all of the precups.  So now I am in the market for a clean complete head.
  
  I was looking at some of the posts about the 1.9 head on the 1.6 block, sounds interesting, I just don't seem to be able to find a complete beginning to end story on it.
  
  Anyone have a source for a complete head.  Maybe a 1.9 head if its not a nightmare.
  
  Thanks and any info would be great.

  
  
  Heads are available, Prothe on this board sells them. not complete though I dont think but you could get what you needed.
• #7 by zukgod1 on 29 Apr, 2008 07:05
• Quote from: "Pat Dolan"

  You might also want to pull the pistons for a good look.  Often when the valves kiss, the crown of the piston distorts the ring grooves enough to seize the rings.
  
  In other words, you may be looking for an entire used engine.

  
  
  I agree on the pistons just replace them but I'm curious Pat, why would you suggest he replace the entire engine?
  
  Looks like he lives in the states and turbo engines are just not that available here. Besides that he can do a easy rebuild for not to much if the bores are ok, new standard pistons with rings and a new head (or repair the current one) and off to the races, sorta speak.
• #8 by zukgod1 on 29 Apr, 2008 07:17
• chrisrandle1
  
  Can you get us a pic of the cracks in the precups?
  
  The cracks in between the valves is normal unless they go DEEP..
  
  I just remembered.
  
  I think I can get complete heads (TD) for $850.00 + shipping.
  I don't know if that's a good deal or not but it's a option I guess.
• #9 by chrisrandle1 on 01 May, 2008 00:11
• Hello again with some updates
  
  Today I poured gas into each port to see how tight the valves were.  I don't know if this is a good test but the valves did not leak any of the gas.  So I am starting to think that they are not bent.  I am actually considering just putting the head back on the way that it stands.
  
  The cracks are fine and I think they are the normal cracks that you find on these heads.  If I can get away with this I can spend money on other upgrades.
  
  Anyone think that is a bad idea?
• #10 by gldgti on 01 May, 2008 01:55
• you want to be sure - drop the valves and make sure they arent bent - heck if they slide out easy then they must be straight.
• #11 by chrisrandle1 on 02 May, 2008 22:45
• So another question for you guys...how in the heck do you get these valves out.  I have a valve spring compressor that has worked for all of my other projects but there is now way it will work for this one.  Special tool?
  
  Another question is where to find the tool needed to get the injectors out.  I read somewhere that somebody had used an extra deep 27mm, but I can't seem to find one.
  
  Thanks in advance
• #12 by RabbitJockey on 03 May, 2008 07:46
• i;ve heard of sticking newer lifters in out of a newer 2.0
• #13 by zukgod1 on 03 May, 2008 21:22
• Quote from: "chrisrandle1"

  So another question for you guys...how in the heck do you get these valves out.  I have a valve spring compressor that has worked for all of my other projects but there is now way it will work for this one.  Special tool?
  
  Another question is where to find the tool needed to get the injectors out.  I read somewhere that somebody had used an extra deep 27mm, but I can't seem to find one.
  
  Thanks in advance

  
  
  I used the same spring compressor I bought for any engine. I used a O2 sensor socket sitting on top of the spring and compressed it, then used a magnet to remove the keepers. Reverse process to reassemble.