Now on to the interesting bits
Originally, the engine was only supposed to be upgraded on the turbo and exhaust departments. But you know how it always goes...
Before I knew it, my power goal had grown from 130 hp to 150 hp and finally 200 hp...
So all sanity was left behind and we set to build a true 'monstah' with my friend Aki, at whose garage the following pics were taken.
Here's some of the main ingredients:
...On the back ground you can see Aki's own 1.9 TD project engine that in it's latest incarnation pumped out 260 horsepower with both a blower and a turbo (!) Now he's gonna put in a multi-valve head and twin turbos... you know, the usual.
As for my engine, this is the recipe we will be following:
1.6 TD block with 0.5 mm oversize pistons (SB-block)
1.9 AAZ head, ported and combustion chamber smoothed out
AAZ-camshaft with 'R-koneistus' reground profile
AAZ three-layer head gasket
Aki-design special head studs and nuts
1.9D (1Y) exhaust manifold modified for a T25 flange
1.9D (1Y) inlet with a WRC-style twin-plenum
Schwitzer S1BG -turbo with 40/47 mm wheels and a 16 psi actuator
2.5" 'Group A' stainless steel exhaust
Twin-Downpipe with a separate pipe for the waste gate
55x23 cm front-mount intercooler
External oil cooler with a thermo-controlled adapter
Top Secret injection pump with 11mm head
AAZ injectors
Main girdle for the block and 1Y oil baffle
We'll see how it turns out, but I suspect it's going to be fun!
The special injection pump looks like this. The bolts are only there to protect it from dust..
The special steel head studs fitted to the block. These have zero stretch, and will really help the head gasket to seal.
A heap of performance parts and an almost new AAZ head. I almost feel sorry for the poor thing...
The famous main girdle. Will help hold the famously fragile bottom end in one piece. We will be using stock con-rods which are flimsy, but with careful matching of the turbo, injection pump and camshaft we will make this engine 'a revver' while the low-down torque is limited. That's the key to longevity with stock internals.
The head test fitted onto the block. Looking good!
And yes, that is a cast iron exhaust manifold from a normally aspirated diesel!
Test fitting the turbocharger. The exhaust manifold collector is farther away from the block's center line so we'll turn the turbo the other way.
That'll also make it easier to make the downpipe, boost and inlet pipework.
The 1Y inlet manifold will be further modified and fitted with a twin plenum that's crucial to divide the air flow evenly among all four cyliders. That's something the stock manifold doesn't QUITE do
Unfortunately this won't fit on the AAZ head un-modified. I didn't want to go drilling / tapping the AAZ head because I somehow suspect I may have to change the head at some point