Mods for an 82 Audi 4000 diesel

[DutchTouch]

I've picked up a project car, an '82 Audi 4000 diesel. Basically a 1.6l NA motor.

I'm in the process of having the head off and getting a valve job, due to a blown head gasket.  This motor makes 52hp stock. I was wondering what I can do to  get some more hp.  Maybe TD nozzles and adjust the injector pump for more flow? Looking for best bang for the buck.
 
It's going to be hard for me to drive this... my daily driver is a 96 Passat that's chipped and nozzled with 520's.

[jackbombay]

TD and NA nozzles are the same part, you can adjust the pump, but it will smoke if you add much more fuel.

Pump adjusting

[DutchTouch]

What about aftermarket nozzles that are bigger, by Kerma, or shimming to a higher break point for beter atomization of fuel???

[fspGTD]

Governor mod: http://www.vwdiesel.net/phpBB/viewtopic.php?t=2300

Cost = $0, change in performance = night and day

[DutchTouch]

Will this work on a normally aspirated 1.6l motor?  What about smoke?

If i'm going to go in and do the injector pump, what is the part numbers I need to replace the seals?  Will HG Makelin here in CA have the parts in stock and the price is?

[jackbombay]

What about aftermarket nozzles that are bigger, by Kerma, or shimming to a higher break point for beter atomization of fuel???

Tthey are not necessary with IDIs untill you max out the adjustments on the pump.

[fspGTD]

Personally I've not had any luck with increasing the breaking pressure of injectors on an NA diesel.  It just seemed that it made that the idle rougher due to the timing belt being dynamically loaded higher.

Increasing the fueling might get you a touch of extra power, but it will come with lots of smoking and potentially dangerous EGT levels.  Replacing old nozzles that may be shooting bad with new fresh ones that spray a nice cone-shape mist is a good idea to get the best power and fuel economy out of your motor - as is other common engine tune-up.

I haven't scientifically tested the governor mod on a 1.6lNA as I have done on a 1.6lTD, but I believe that it would serve a 1.6lNA even better than a TD due to the 1.6lNA's relatively longer intermediate spring travel.  I'm guessing that on a car set up with fueling on a verge of smoking, that it may cause a little bit of extra smoking at high RPMs that would not otherwise be present.  But if you try it, report back on how it works so we can all benefit!  If you find that you don't like it, you can always revert it back to stock if you save the intermediate spring and keep track of what shims it originally was set up with.

If HG Makelin is a diesel specialist, they would be a good bet for supplying you with a VE pump rebuild/o-ring/gasket/seal kit.  I haven't heard of them before though.

[DutchTouch]

HG Makelin is located in San Francisco and is a Bosch parts Dealer. They had the seal kit for the Bosch VE injector pump on my 96 Passat TDI when it started weeping and leaking fuel.


I found this little goody tonight for doing my cam belt and setting the timing.

It's a full blown shop manual in PDF format.

http://www.fostertruck.com/Files/VW_diesel_77-83.pdf