Skoda Pickup 1.6/1.9 head BV50 project - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• Skoda Pickup 1.6/1.9 head BV50 project by barrygti on 11 Apr, 2009 22:44
• I got fed up working on my WR480 big bore Supermoto project today so worked on something else....
  
  
  
  I found just about the only Skoda Felicia Pickup in New Zealand that an ex-pat had brought out with them, they then ran it through a big puddle and bent a con rod. My original plan was to get friends in Scotland to get me parts to fix, but then I decided to go a little further.
  
  
  
  I have a couple of variable vane turbos from Land Rover TDV6 engines, now they put out 190bhp and 325lb/ft as standard so I am hoping 200bhp is possible on my engine, although it may be slightly too large.
  
  
  
  The standard engine is 1.9d NA. I am planning to build a frankenstein with 1.6 bottom end and the 1.9 head which is much better for flow, I will also do a bit of light port work to it.
  
  So today started with me removing the standard inlet and downpipe and trying to work out how to fit the turbo, first problem.... I can't clock the exhaust housing due to the variable vanes so trying to sit the turbo so that the oil inlet and outlet are vertical is tough. The below picture is as best as I can get it:
  
  
  
  
  
  Now this means I need to get a little adapter pipe made to go from the manifold to the intake of the exhaust housing, it also means the downpipe has to come out and bend down pretty tightly but I will make it big to compensate.
  
  
  
  The variable vane actuator rod will also sit close to block so going to be a pain to adjust, this will be actuated by the throttle pedal, basically when the pedal is mashed the vanes will direct all gases at the turbine wheel and when on partial it will allow some gases to pass to hopefully keep it frugal. I will use the EGR outlet on manifold to run an external gate to control boost so some more piping required.
  
  This is the inside of the standard intake, obviously there are 3 more ram pipes.
  
  
  
  Now I like this design so I am going to try and get someone to make a copy of the top plastic part in aluminium, as I fear the plastic will explode
  
  
  
  Next I removed the bumper to trial fit my Land Rover intercooler, what a BASTARD it was getting the grill out the ***er!!
  
  Anyway I have cut the tank outlets, will get these welded and have the new outlets at each end of the tank.
  
  
  
  
  
  After that I took the head off just to check it, and there was none of the cracking between the valves they normally have so it's a top class head!!
  
  So just waiting on the 1.6 engine to arrive to strip down and will get head cleaned and stripped at work next week.
  
  What do you all think? Any help or ideas appreciated...
• #1 by hamradio on 12 Apr, 2009 07:19
• Wow.  Very neat project.  I must ask, however...why are you using the NA manifold and converting it to work with the turbo, over shipping an aaz TD manifold in from somewhere?
  
  
  I'm highly envious of your little pickup.  
• #2 by the caveman on 12 Apr, 2009 08:11
• I'm also interested in that intake. What engine model is it from. Just the thing i need for my 1.9 na Transporter.
• #3 by barrygti on 12 Apr, 2009 13:30
• The trouble with the intake is that in the Skoda the engine sits more upright than in VW's. So I fear that some of the other intakes will be too high.
  
  I don't have my 1.6 engine yet so can't compare that, but I like the internal design of the manifold, so assuming I can have a lid made cheap enough I will be happy.
  
  The engine code is AEF.
• #4 by TurboJ on 12 Apr, 2009 15:19
• Whatever you do with that inlet manifold, don't use a stock TD one!
  They suck big time. Either use a gasser manifold or make your own.
• #5 by barrygti on 12 Apr, 2009 15:26
• Well that's that Idea sorted hahaha.
  
  I am having some thoughts of maybe putting the 1.6 engine back in this to just get it running and buying something else to build my good engine in to.
  
  My big worry with the Pickup is that the Skoda gearbox is a little weak, it is not VW based. So maybe a Mk3 Golf or similar would be a better base for 200bhp.  :?
  
  Will wait until the 1.6 engine arrives and work it all out.