1.6TD issues.........

[mean88]

I have a 90 jetta wolfsburg with a 1.6TD.  It has a 1.5 solid lifter head on it.  Last winter the timing belt skipped off and slammed the valves into the pistons, so I got the above head off a car in the junkyard for 50 bux.........

The car started easier initially with the smaller cc head.  This summer though engine is getting tired.  It starts on 2-3cyl and smokes white on cold startup.  Even when it is still warm I need to glowplug it........It smokes like "uncle bucks" car when I drive it under heavy load, and it is a dog.........it still gets decent mileage though......

I got a best of 48.5mpg with it this summer to and from work 50 mi per day.......................now its in the high 30's low 40's

The car is still in decent shape with little to no rust.  The paint isnt the greatest, but like I said its a work car that I depend on. (the damn door handles suck!!!)LOL  So I dont want to get rid of the car.

I dont know what to do right now.  I see low mile 1.9L engines with a high ratio trans on ebay for 2700ish.  I thought of a complete swap................

Part of me thinks I would enjoy rebuilding this engine more as I am a Mechanic for a living. 

So, dollar for dollar what is the best plan of action??

I also plan on adding an intercooler either way, the pump and injectors have been recently rebuilt.  I have the fuel screw turned up some too.

I will need a complete head for sure, and a set of bearings/rings/seals........where do I get an overhaul kit, and what type of "NEW" head is the best deal?

My turbo is still tight, my alt is new, and my starter is new too.

Is a 1.9L worth the extra trouble for a work car???

Does anyone know the difference in trans ratio's for my car VS a 3.66-.74 5th trans?

I have more questions, but I will take it slow.

Thanks
Ted

[flapjack]

maybe a silly question but did you try messing with the timing since it started running badly?
heres some gear info:
http://www.scirocco.org/gears/
http://www.vwparts.net/veedub/X-gearcalc.html

[arb]

Yeah, I'd start with checking yoru timing...

On the trans, here's a chart with many of them. Do you have your trans code? It on the bottom of the bellhousing.\

http://scirocco.org/gears/

[mean88]

No I havent checked the timing.  I would assume the white smoke would be too much advance??

[rabbitman]

No I havent checked the timing.  I would assume the white smoke would be too much advance??

I think it's usually too much retarded.

[burn_your_money]

Yeah too retarded. Your injectors could be kaput as well. Most places will pop test them for free so that wouldn't hurt. I know you said they were rebuilt you never know...

The 1.9l engine is great, lots of power but I've never found them to get that good of fuel economy. I have a 1.9NA in my mk2 and it's good. Decent power (relative) and good mileage (usually 5.3l/100)
If you go that route make sure to get the crank pulley problem addressed.

[mean88]

My ultimate goal is fuel economy.  If I can get 1-2 mpg more out of a 1.6, then I am going to rebuild and use a 1.9 head.  I will check my trans code momentarily.

 I had the injectors done last fall at a local diesel shop where I have a friend that works.  I did however run hydraulic oil in my car for a spell as fuel, maybe theyre dirty??  I can pop test the injectors myself at work, we have a machine.........How does one check the timing on one of these engines?  On our bigger tractor turbo diesels we use a dial indicator on the pump and use TDC to find the correct timing. 

[rabbitman]

My ultimate goal is fuel economy.  If I can get 1-2 mpg more out of a 1.6, then I am going to rebuild and use a 1.9 head.  I will check my trans code momentarily.

 I had the injectors done last fall at a local diesel shop where I have a friend that works.  I did however run hydraulic oil in my car for a spell as fuel, maybe theyre dirty??  I can pop test the injectors myself at work, we have a machine.........How does one check the timing on one of these engines?  On our bigger tractor turbo diesels we use a dial indicator on the pump and use TDC to find the correct timing. 

You can read on here about other peoples 1.6 block/1.9 head frankens. Sounds pretty good to me

These are timed the same way with the dial indicator, this shows how: http://vincewaldon.com/index.php?option=com_content&task=view&id=24&Itemid=28

[mean88]

Where are most people getting their overhaul kits, and heads from?  I am sure I can reuse my pistons, they still look good.  How about rings/bearings/seals???  I see different heads on ebay here and there.  I am going to use a HYD 1.9 head, and I am looking for something complete......suggestions???  Any heads/brands/vendors I should stay away from?