Why no 1.6l tdi?

[Rabbit on Roids]

you gotta mill 16mm off an aaz deck to get it to where you want it to be. unless you use some sort of longer rods.

the AAZ is 16mm taller than the 1.6 block.

[oldskool rich]

sumone was telling me that a 1.9 is better because its square, ie the stroke is the same as the bore
is that true?

in my mind it makes sence to have a 1.6 crank in a 2.0 block with PD 8v pistons and ALH head u just need to chop the block down and get custom rods

infact im doing just that in my caddy but with stock crank hoping for sum gud power

[MJF]

1,9 is even nowhere near square. Bore 79,5mm and stroke 95,5mm.

[JRD]

I'm always thinking about a 1.6L TDIm

VW put a 1.6L Common rail TDI engine (called CAYA or CAYB) in the new polo.
Most of the caracteristic of this new engine is similar to 1.9L TDI engine.
I think the 1.6L TDI engine is made from 1.9L engine block with special cranshaft and special conrod.

If it's right, maybe it's possible to do a 1.6L TDim by using the crankshaft and the conrod from a 1.6L CR TDI engine (CAYA or CAYB) in a 1.9L TDI engine (1Z or AFN)!!

Problem: it's hard to find the polo in a scrap yard...  

[RabbitJockey]

you could make a 1.7tdi easily with a 1.6 crank in a tdi block with tdi rods and pistons, you would just need to deck the block down about 9.1mm to get the proper piston height, but this is assuming there is enough webbing in the tdi block.

[RabbitJockey]

how ever due to the nature of how diesel air fuel ratios work, i don't see there being much gain by doing this, maybe slightly better revability due to the short stroke and better rod angles.  but mpg i imagine would remain the same.

[JRD]

The fuel consumption goes down with the engine capacity.

The problem of this engine is caused by the bore who is higher than the stroke, this configuration is normally made for petrol engine to improve RPM...

[JRD]

After lot of research, I hope I've found a solution to make a 1.6L TDI engine.


- crankcase from a 1.6L TD engine
- cranshaft, connecting-rod from a 1.5L D engine
- piston from a 2.5L V6 TDI engine
- cylinder head from 1.9L TDI engine

The result:
- cubic capacity of 1541cm3 (bore: 78.3mm, stroke: 80mm)
- compression ratio 16,1:1



Modification to do.
- Change the crankcase bore from 76.5 to 78.3mm to accept the 2.5L V6 TDI pistons
- Change the diamètre of the conrod from 22mm to 26mm to accept the piston axle
- Modificate the head to improve compression ratio from 16,1:1 to 19,5:1

[MJF]

With quick calculating, V6 piston would stick 3mm higher from block than 1,5 piston.

[JRD]

It's possible.


To ensure it, I need to know exactly the heigt and the axle diameter of the 2.5L V6 TDI piston

[MJF]

http://www.motorenteile.mahle.com/eLIZA/mahle/query/engine/byParams

Good source for dimensions.

[JRD]

Thanks a lot!

[R.O.R-2.0]

After lot of research, I hope I've found a solution to make a 1.6L TDI engine.


- crankcase from a 1.6L TD engine
- cranshaft, connecting-rod from a 1.5L D engine
- piston from a 2.5L V6 TDI engine
- cylinder head from 1.9L TDI engine

The result:
- cubic capacity of 1541cm3 (bore: 78.3mm, stroke: 80mm)
- compression ratio 16,1:1



Modification to do.
- Change the crankcase bore from 76.5 to 78.3mm to accept the 2.5L V6 TDI pistons
- Change the diamètre of the conrod from 22mm to 26mm to accept the piston axle
- Modificate the head to improve compression ratio from 16,1:1 to 19,5:1

sorry, but your not going to bore a 1.5 rod small end out to have enough meat left to have a bushing in the end, and hold a 26mm wrist pin..

time for another solution.

[JRD]

  Same player shoot again...

[JRD]

http://www.motorenteile.mahle.com/eLIZA/mahle/query/engine/byParams

Good source for dimensions.

They don't have informations from 1.2L 3 cylinder TDI engine.
I tried the kolbenschmidt site but without success.

Do you know who manufactured this pistons?