Fantasy 1.6 TD - Fresh build, what parts to use.

[Baxter]

Okay, blank canvas.
Got a Caddy, 1.6D
Engine is a little tired, still goes well, rattles a bit, don't think it's long of this world with my driving!
So, there is a VW breakers 'round the corner.
They have sheds full of engines in various stated of disrepair.
I fancy building a 1.6TD for it.
So, is there any head thats better than any of the others? Is it just this type engine number is the best one as a base?
I have a dead 1.6TD JX (70 bhp) from a T3 (Vanagon)
I looked into 1.7 D pistons, but they seem to be 79.5 bore so that rules that out.
Do the flywheels respond to lightening and balancing?
Will it be a case of buying a Passat (Quantum?) and swapping its engine into the Caddy and bolting on a intercooler and playing with the pump?
Info on tuning Diesels is hard to find!
Is there a certain turbo thats any better than the rest?
Sorry, lots of questions, sure you know where Im coming from!

[Baxter]

Surely someone must have some thoughts on this?
My local VW breakers are having a clear out, need to  know what parts to look out for!
Theres heads, blocks, turbos. intercoolers just laying around in the mud, bit disturbing really, all seems such a waste.
Already got a MKI GTI oil cooler filter head, with the M10x1 to M14 thread adapter for the oil feed pipe for the turbo.
Is it just a case of finding a SB or RA engine?
Is there a better turbo to have?

[malone]

I'll be the first to chime in with some light info.

So, is there any head thats better than any of the others? Is it just this type engine number is the best one as a base?

My 1.6TD is being rebuilt (by 935racer) and instead of re-using my 1.6TD head that is fine, we'll be using a AAZ 1.9L TD head I picked up this week. The 1.9 head has larger valves and better airflow potential with some porting. It will go on my 1.6 block.

Do the flywheels respond to lightening and balancing?

I would ask DVST8R, clicky.

Is there a better turbo to have?

I don't know the best OEM TD turbo to use, especially in Europe where there's a bigger variety of diesels. However, I have a couple questions: What turbo do you currently have? What kind of driveability are you looking for?

Personally, I like larger turbos that flow well in the upper RPM band, but there's hardly any boost in lower RPM. However, I have a Giles (Superior Fuel Injection) pump that performs exceptionally well off-boost, so I'm happy. A KKK K24 would be the OEM TD turbo of my choice. The Garrett T3 would be a close second. Both turbos can be found on 1.6TDs.

Some people prefer smaller turbos that spool up quickly; this is nicer for daily driving. A KKK K03 from the 1.9TD or a KKK K14 from a 1.6L ecodiesel will suit this nicely.

My dream setup is to have a compound turbo with a stock KKK K03 from a 1.9TD as the small turbo, and any larger turbo. Results in quick spool in lower RPM and decent flow up to redline (approx. 6,000 RPM with Gile's pump).

[Busdriver]

Won't using a 1.9TD head on a 1.6TD lower the compression ratio?

[935racer]

I've wondered if it would as well, but yesterday as I was test fitting the head to the block I don't really think it would, or at least not that much, the lower compresion ratio would actually be nice for how much boost this engine is going to run. Perhaps I'll blueprint the engine...