1.6td questions.

[kaneb]

hi,

As you can see im new.  A little background, I do heavy diesel mechanics for a livingand for a fun project i bought an 83 rabbit diesel.  i drive an 03 golf for a daily, i love vw! The rabbit has a 1.6NA and I have bought a 1.6td which im in the process of re-building.  Well i have it tore down i have some questions.  I need to reseal my pump, replace mains and rings, going to go with arp head studs.  Can anyone point me in the direction to buy this for a good price.  And what model number of arp's studs do i need.  
My plan is to re build the engine, intercool, run 3" exhaust, new injectors, govenor mod on the injector pump and port and polish the head.  From what i've read here from my lurking this should be a nice jump in power from my NA.  oh yeah i belive my turbo is the k24.

Anytips and help will be appreciated on this build.  I will surely have more questions to come.

Thanks in advance,
Kane

[TurboJ]

1.9 TD (type AAZ) head would be a useful mod. Flows like 10% more stock, and with porting can support quite a lot of power.
You can get about 150-160 hp reliably with the K24 turbo, but you're going to need more pump mods than just the gov to achieve this. Namely a modified boost pin, and most importantly a bigger pump head.
Your stock pump with gov mod should allow 120-130 hp.

About head studs: All the VW 8-valve stud kits should work.

[kaneb]

I'm looking for 100-120 HP in this car.  After the engine is rebuilt and running and i have broken it in i will want to up my boost.  Im planning on putting EGT, Boost and of course an Rpm gauges to monitor how its running.  Any opinions and advice on this is appreciated!

Anyone know of any good online sources to pick up some arp head studs, a head gasket, rings and mains and and a injector pump seal kit.

Thanks for the input turboj.  The 1.9 head would be nice but i think i will stick with just the 1.6 as for now unless of course i find a 1.9 at ease and at a good price.

Kane

[monomer]

http://oak.cats.ohiou.edu/~mw105397/dubdoctor/parts_site/

for most stuff


ARP can be bought from www.headbolts.com this is where I ordered them. it was just over $400 for con rod. mains and head studs.


Total seal rings can be found at: http://www.racetep.com/totalsealframe.html I recommend running them (you have to call and order a custom set.)


everything else I got from autohauaz

[kaneb]

Thank you,

some more questions out of this noob!  i found this site http://www.dieselvw.com/  I was thinking of getting most of my parts there order at once and have it shipped up to me.  Of course there is the currencty change in money but prices look good.  Any of you buy from them?  Service and product good?

Any info is appreciated.

Kane

[TurboJ]

1.6 head will be fine for 120 hp, but usually the power goal goes up after the first engine is built

[Vincent Waldon]

Thank you,

some more questions out of this noob!  i found this site http://www.dieselvw.com/  I was thinking of getting most of my parts there order at once and have it shipped up to me.  Of course there is the currencty change in money but prices look good.  Any of you buy from them?  Service and product good?

Any info is appreciated.

Kane

In the "For Sale" forum there's a Buyer-Seller feedback thread with some data on this vendor.

[kaneb]

Thanks again guys!!

After some more research plus i was out today and stopped by concept1(local vw/audi performance shop)  I got some prices and they sound pretty decent to me plus supporting the local company.  I picked up a bentley manual as well.  Im sure ill have more questions as well soon.  Any way ill have a build thread up for the rabbit soon.  

Plan so far for engine.  Thoughts, opinions and critics welcome.
Car is an 83 rabbit.
-pnp the head
-arp head studs
-metal headgasket is what my plan is(do i have t do some mild modification at all to make this work, thought i read that some where?)
-full on rebuild on the bottom end rings mains(havent decided about arp rod studs haven't researched enough about them yet)
-have a k24 turbo, want to run  around 17-25ish boost if engine is strong enough will see when i get there. thats possible right?
-3" exhaust down pipe all the way back probably have to oval over rear axle beam.
-intercool-probably purchase through ebay seller "just intercoolers"
-hardwire fan to a switch so i can manually turn on.
- gov. mod on injector pump(its getting completly resealed)
-possibly different injectors or nozzles(need more research on them, anything you reccomend?)  

Thats my somewhat list. i know i've mentioned already most of it.  What kind of HP is achievable after this is done do you guys think?  

Hopefully i can finish the build and have in car by the end of winter.

[TurboJ]

With those mods you should be able to get about 140-150 hp.
And there's nothing important missing really, just make sure you have a good suspension and brakes as well, so you won't end up in a ditch  

[kaneb]

wow really?

I didn't know i would have that much hp, anything over 100 is good,well better then the 52hp i have now.  I will be lowering the car with some vmaxx coilovers some strut bars too, and some 13" rims(something fairly light).  Brakes i have upgraded on the front.  Back are still drum, wouldn't mind putting disk on.  First power rebuild though.  Put in suspension during the break in period...a little time to save some more coin.

kane

[kaneb]

Ok so tomorrow im finally starting on this beast.  Starting with the head. clean it up and pnp.  also going to clean a lot of the smaller parts and get them preped for going back onto the engine.  Then the end of this week off for a vacation then ill be in the garage.  
I pretty much have everything figure out except for this. Headgasket.  I want this engine to run fine at 17-25ish psi of boost.  I've heard modding the metal gasket for the aaz.  And i read one member is sending out for a custom made one. Any suggestions?  I want to be at peace of mind when this is all built, so im trying to rule out a fiber gasket.  Don't know if this helps any but the engine has hydralic lifters.

Any input is welcomed!

Kane

[arb]

Any progress ? Any photos ?