New to the 1.6TD

[MJF]

True, but at what rpm range?

One for example, 19psi boost. With 32psi, I had 150hp between 3600-5900rpm :lol: Lowered it to 29, it got faster. Thanks to vnt :roll:

Has anyone tested propane for VW idi? I know one and it didnīt add any hp for him :?

[blacknoise]

Before you go crazy, look at the toque/power curve for your nominally stock 1.6 turbo diesel engine.  I ripped one from a 1983 SAE paper (i have it printed, but not here) on the topic of adapting the VW diesel for turbo-charging in the case of the four and five cylinder versions (of course there is also a six for Volvos).

Honestly, I have the image locally on the computer, but can't get it on the post right now.  Maybe I can PM it to you

[arb]

Honestly, I have the image locally on the computer, but can't get it on the post right now.  Maybe I can PM it to you

Save the image to paint... save as .jpg and upload it to http://www.photobucket.com - from there you can post the link on our board :-)

[Richmond69er]

thanks for the heads up on turbo choices...

been reading up on it and have decided at the moment to go hybrid with a k24/26 i dont want to run what i have now and be maxed out to the limit... exhaust manifold i was planning on fabbing one up.

ive been calling around trying to source parts out around me locally but i thikn im going to have to start looking elsewhere... any tips? besides whats on this forum?

ive basically decided on my turbo, exhaust, exhaust manifold.

im still looking around for FMIC ideas and intake...

now another queston i have is what kind of injectors to use? surely stock ones need to be changed out...
id really like to have all the parts before i tear this thing up... that way i can blow it out in a weekend or whatever...
tranny work will come after the motor is built.

[MJF]

If stock injectors are good, there is no need to change those.

[subsonic]

If stock injectors are good, there is no need to change those.

They should give all the fuel you need.  I saw that you said you did the injectors already.  Did you rebuild them, nozzles-lapping-correct 155 pop pressure etc..?

If you are going to be tearing the engine down, and have access to a lathe, you may want to turn your intermediate shaft to true it up.  Takes about 4-6 ounces off and balances it.  Not gonna gain you 10hp but every bit helps.  Here are some before and after photo's of mine:




Here is a link to the thread that discusses it.
http://vwdiesel.net/phpBB/viewtopic.php?t=13253&postdays=0&postorder=asc&highlight=intermediate+shaft&start=0

If you can get a good parts list together, people on here will help you find the best deal.  We all love to score the best deal!

[BlueMule]

Rich, hello I wish you success with your project. I crunched some theoretical numbers and here is an interesting look at how RPM and Air flow can affect HP. From mild to wild, here we go

All calculations done with a 1.6L engine, boost in PSI,  

                   
RPM  3500  Boost  10   BHP  70    Air Lb/Min   8.5    Intercooler  No
RPM  3800  Boost  14   BHP 100   Air Lb/Min  12      Intercooler  Yes
RPM  4400  Boost  18   BHP 130   Air Lb/Min  16      Intercooler  Yes
RPM  4800  Boost  22   BHP 158   Air Lb/Min  19      Intercooler  Yes
RPM  5200  Boost  26   BHP 189   Air Lb/Min  22      Intercooler  Yes
RPM  5800  Boost  30   BHP 229   Air Lb/Min  28      Intercooler  Yes

I like # 3, I will not be at 4400 all the time, but if I need more power I know it will be there  

#6 is all out, a forged crank, Carrillo rods, pistons machined for Teflon buttons, in fact lets put in a stroker crank overbore to the water jackets, sleeve it and build a 3.0 4 banger, hmmm now that i think about it, were is that budget spreadsheet  :lol:

[subsonic]

If you are not going to invest in high dollar custom connecting rods, you may want to consider improving the stock rods. They are very robust, but high boost at low rpm will really stress them.  Resize big and small ends, arp con-rod bolts, polish and shot peen.  You can polish them yourself and just have them shot peened.  I lost about 1 ounce per rod.  Needless to say you should have the rotating assembly balanced when you are all done.  Here is a photo of mine after being polished and shot peened.

[Rabbit TD]

RabbitTD....

those perforations in the muffler.....
i have a magnaflow turboback installed on my truck and the muffler can be turned around (one way the exhaust flows straight through over the perforations and the other way  flows through but catches on all the perforations in the muffler)

maybe check that out and see if ur muffler is like that or not...

This one isn't made that way, it is a 5x9x18 oval type with the inlet and outlet both in the center of each end and it is straight through with just holes and not louvered, doesn't matter which way you put it on.  I did leave the resonator that was on the part of the exhaust from the Jetta on thinking the car would be pretty loud but I'm pretty sure it's gonna be coming off.   It sounds now like a vacum cleaner with a little bit of a buzz added.  :lol:

[Richmond69er]

subsonic....

thats a great read. i just cruised through it and it seems like a good idea when i have the motor already torn down. ill give it a few passes on my lathe.

as for rods...i am looking at getting some custom connecting rods instead of sticking with whats in there... but if the price tag scares me away ill definitely be messaging you for some more info..

about the injectors. they are brand new they run mint  

but today i was talking with a close friend of mine and we came across a wrecked 01 Jetta TDI in portland. its a rollover car so the shell is garbage but the motor and trans is still good. 115k on it. were going to go trailer it home this coming weekend for parts. we were tossing the idea around of just swapping in the 1.9tdi motor in. what do you guys think? i kind of prefer the 1.6td just because theres no computer involvment

[subsonic]

I think it would kick butt!  For about the same price as giles rebuilding your td pump you could have him build a brand spankin new mechanical tdi pump built.  When you ditch the ecu, making power goes old school again, fuel-boost-exhaust.  Toss in a 1749vb or gt20 and you will have a screamer, 150-200+hp.  The tranny will be more robust as well.  Sell off the 1.6TD engine for a good offset and you will be on your way.

[Richmond69er]

I think it would kick butt!  For about the same price as giles rebuilding your td pump you could have him build a brand spankin new mechanical tdi pump built.  When you ditch the ecu, making power goes old school again, fuel-boost-exhaust.  Toss in a 1749vb or gt20 and you will have a screamer, 150-200+hp.  The tranny will be more robust as well.  Sell off the 1.6TD engine for a good offset and you will be on your way.

ill know for sure what i plan to do after this weekend after i get the car in my garage...for the price of the parts/donor car im practically robbing the guy.

ill have to research it more, just curious to see how much fab work its going to take to get the TDI motor in the mk2.

offsetting the price of the parts car by selling off my 1.6td is a good idea... but i also have a project suzuki samurai that id love to put the 1.6 in.

To many projects to little time! isnt that the case all the time!!!  

[one_tinted_tail]

hey 69er, to be honest, beating mk2 VR's with just power is a tough task but I whooped a friend with a mk2 VR golf another with a VR passat and another with a mk4 GTI stage 2 (all on twisty PA backroads(&on veg)) and im convinced it was me, the driver, with a courteous nod to my giles pump that facilitated these kills..

Im running bilstein struts with H&R(3/4" drop) springs and new OE bushings everywhere else. also, green diamond tires and less cetane than diesel on my vegetable oil ... get comfy with the cassis, then work on power, ,,in my opinion, which like my a**h*ole is one of many  :wink:

[Richmond69er]

hey 69er, to be honest, beating mk2 VR's with just power is a tough task but I whooped a friend with a mk2 VR golf another with a VR passat and another with a mk4 GTI stage 2 (all on twisty PA backroads(&on veg)) and im convinced it was me, the driver, with a courteous nod to my giles pump that facilitated these kills..

Im running bilstein struts with H&R(3/4" drop) springs and new OE bushings everywhere else. also, green diamond tires and less cetane than diesel on my vegetable oil ... get comfy with the cassis, then work on power, ,,in my opinion, which like my a**h*ole is one of many  :wink:

that sounds awesome.

i dont know what kind of vr's guys are running over there... but i went on a few cruises with the VW club here and in all honesty. my car just could NOT keep up. straights, turns, etc etc doesnt matter what it was. but most of my buddies are running stage 2 or stage 3 VRT's so they are putting out HUGE numbers....

we have a shop locally called JS performance and they are currently doing the R&D on the first compound turbo setup on a 1.9TDI... its going to be costly but its in the back of my mind as a mod that i would definitely consider doing if i swapped out my 1.6 for a 1.9.

to each there own! but thats impressive that you managed to run away from VR's

[one_tinted_tail]

I am talking about a very curvy road I drive everyday like mad, as for highway stuff or relatively straight roads, i would(&have) get pissed on for sure.

Although, it was a V6 A4 and VR passat I led to a past car show and was the one who got pulled over.. he said I was doing 95 bla bla bla .. the courts still havent proven their jurisdiction over me and the papers ive filed bar the judge and officer from standing in truth before me in court, but thats a whole nother story...