My 1.6TD/1.9 head build Thread. - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• My 1.6TD/1.9 head build Thread. by monomer on 29 Sep, 2008 14:33
• Stats:
  
  - .020 overbored Turbo pistons (ceramic topped)
  - Glyco Main bearings
  - Total seal ring set
  - 1.9 Hydro head
  - Poly engine mounts
  - Spec Stage 3 Clutch kit
  - Full ARP stud/bolt kit (mains/head studs, con rod bolts)
  - VW oil squirters
  - Wastech EGT gauge/probe
  - VDO boost, oil pressure/temp and coolant temp gauges
  - Instrument cluster out of a gasser (w/tach) (still researching on howto use this)
  - Techtronics short-shift arm; new shifter bushing/linkages (maybe a USRT kit instead)
  
  
  Turbo setup:
  - Mercedes t3 (off of a 92 300d) (this may change)
  - T3 flanged exhaust manifold
  - TiAL 38mm External wastegate
  - Stock Subaru STI intercooler (I dont know it I want to try top-mounting this)
  
  Injection:
  - Giles turbo pump, rebuilt injects (per giles recommendation)
  - Walbro FBR-11 lift pump
  - Styadyne filtering
  
  This is getting dropped in my nearly rust-free 1983 VW Rabbit. Comments/suggestion welcome. I'll keep adding stuff as questions comeup
• #1 by gigaz2 on 29 Sep, 2008 15:05
• lift pump might rise your IP internal pressure, you don't want that in a IDI as it screws up the dynamic timing.
  how will you control the IP intake pressure? it works on "vacuum" in stock form
  
  also, is that cluch designed with diesel in mind?
• #2 by monomer on 29 Sep, 2008 15:30
• Quote from: "gigaz2"

  lift pump might rise your IP internal pressure, you don't want that in a IDI as it screws up the dynamic timing.
  how will you control the IP intake pressure? it works on "vacuum" in stock form
  
  also, is that cluch designed with diesel in mind?

  
  
  
  I've read the Pumps do not cavitate easily. This pump operates at low PSI and automatically adjusts flow to demand. This pump is designed for this application, as the IP will not pull enough fuel on it's own during high boost periods.
  
  
  The clutch is designed for diesel. Ordered from 034 motorsports. 6 Puck with carbon friction surfaces.
• #3 by Smokey Eddy on 29 Sep, 2008 23:43
• OH THANK YOU! IM DOING THE SAME!
  Yesssss someone who knows what they are doing!
  Thank you! Thank you! Thank you! Thank you! Thank you! Thank you! Thank you! Thank you! Thank you! Thank you! Thank you! Thank you! Thank you! Thank you! Thank you! Thank you! Thank you! Thank you! Thank you! Thank you!
• #4 by monomer on 30 Sep, 2008 18:35
• I still have a lot of questions myself.
  
  
  I have no idea what I'm doing as far as intake manifolds go.
  
  
  I need to look into everything required for this head swap, and possibly o-ringing this head.
• #5 by Jet A on 02 Oct, 2008 16:17
• Get one of those regulators for the pump. screw it down to 4-7psi and let it rip.
  
  Install it before the filter, which will help drop pressure, and prevent entrained air.
• #6 by subsonic on 02 Oct, 2008 16:39
• What are your questions re the intake?  O-ringing  has been done in the past on a aaz by andy2.  Remember, you will need to go around the prechambers.
• #7 by RabbitJockey on 02 Oct, 2008 19:05
• i think what dave was saying, is that if u have good flow with a ported head and a good intake and exhaust manifold, that it helps to keep the head from lifting, along with not having high boost at low rpms, that was the problem with andys car, he had that little turbo or what ever.
• #8 by Smokey Eddy on 04 Oct, 2008 12:07
• I'm going to be runing a TDI intake that goes to my intercooler. the 1.6 intake doesn't fit on the 1.9aaz head i've been told but a TDI one will. but if you go that route you have to do your own plumbing to the turbo.