Update:
I mentioned that a 52HP NA pump was swapped into my MK3 in January or February while the modified pump is supposedly going back to Giles for an upgrade. The engine still started up and ran like new, even after the abuses last Fall with the extensively modified LDA pump. However, this month I had problems with the water pump. Overheating occured and my cylinder walls are now scored. This is why I bought a 1984 Rabbit 1.6D a week ago to temporarily use as a daily driver.
On the bright side, the 1.6TD block was stock unlike the rest of the engine/car. It's unlikely the block + 020 transmission will hold up to the ultimate power with the upcoming boost + fueling increase. I've always been bugged thinking "we should have done something to the block at the beginning," now here's the chance. DV8STR's O2J transmission is also in the shop waiting to be installed.
The 1.6/1.9 engine had approximately 10,000km (6,200mi) on it until the coolant problem. We've gone quite far in terms of engine build so I don't want to flush it down the toilet. The power the 1.6/1.9 had with the modified pump was mind-blowing and I can see a lot more potential with better airflow/fuel flow. fspGTD also made my custom fuel nozzles this year and I've got to put it to the test!
Importantly, I received news that I landed a new permanent job within the RCMP. Finally! I've been waiting for that for almost a year. I will buy a new daily driver that will be at best mildly modified (we'll see :lol:), and the 1.6/1.9 project will be my second car/track racer.
Even though a daily driver will help me ensure the 1.6/1.9's longevity by not forcing to drive it daily while it should have received any maintenance it needs, we still need to put a little more effort in keeping it healthy this time around. The basic coolant issue was ridiculous and could have been avoided in the first place. The next engine build should be done properly with new water pump etc.
The 1.6 block may be bored out for 1.9L AAZ pistons, and custom rods installed, making it a 1.7L. The AAZ pistons are also better suited to my 1.9L TD head. We've seen andy2 bend his rods. To mate AAZ pistons to the 1.6 crank, custom rods are required, so TDI rods are out of the question. Also, I'm not interested in the 1.9 crank + TDI rods + 1.9 piston assembly. I prefer to retain the 1.6 crank, which may be nitrated or cyroed.
The new daily driver may be a TDI. I have the business of chip tuning TDIs so it's nice to have a demo TDI vehicle. I'm also going to shop around for a new home this year, preferably with a garage (currently don't have garage space). These are factors that may slow down the 1.6/1.9 progress this year only. However, finally having a garage will mean good things for my diesel vehicles.
My 1997 MK3 needs paint (
$50) and suspension replacement (free, FK coilovers are under lifetime warranty), which could be done in the meantime.
BTW I still admire IDIs more than TDIs because of the simplicity and how effective they are with performance.
I'm debating on whether to keep my 1997 MK3 shell or sell it with a stock 1.6TD, and move the 1.6/1.9 to a clean German Rabbit. MK1s feel a lot more tossable; more fun to drive. The -600lb weight advantage is nice, too.
edit: I'd also like to note that during some hard (est. 170-190bhp) runs, my coolant tank spat out coolant even after replacing the tank and cap. It looks like that Raceware head studs and the 1.9 headgasket cannot hold the head and block together sufficiently. So a $75 USD copper headgasket and/or o-ringing the head and/or block will be a good idea to keep the motor solid.