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Author Topic: My 81 vw pu 1.6 na to td build  (Read 35017 times)

May 02, 2010, 01:10:20 am

81 vw pu

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My 81 vw pu 1.6 na to td build
« on: May 02, 2010, 01:10:20 am »
First of all i'd like to say hello and thanks for all the information i've got from reading on this forum. This is a tdi setup that i purchased about 1-1/2 years ago before i came across this forum. ( and yes its from proth). Here are a few pics or my 81 vw pu 1.6 na to td build. I've been gathering parts for over a year to put a tdi turbo setup on a 1.6 na. i'm just mocking everything up now on a spare 1.6 and then i will transfer it to my pu.







81 vw caddy converted from 1.7 gasser to 1.6 NA. Diesel W/ FF 5 speed.
1.6 TD intake and exhaust w/k14 turbo,intercooled, 2.5" straight pipe. NA. pump with govenor Mod and a 50 shot of nitrous!!!

Best 1/4 mile pass= 16.8 @ 85 mph

2003 TDI Golf  1.9 ALH 2.5" catless downpipe, EGR delete

Reply #1May 02, 2010, 07:15:54 pm

8v-of-fury

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Re: My 81 vw pu 1.6 na to td build
« Reply #1 on: May 02, 2010, 07:15:54 pm »
That looks mighty fine what you got there, it will sure to be a real runner.

However there are some things you need to verse yourself on ;)

The VW 1.5, 1.6, and early (1993-1996 and some thereafter) 1.9 are IDI or Indirect Injection engines. The newer 1.9 (1996 Passats, 1997 and on Jettas, and 1998 and on Golfs) and later "Clean Diesels" are TDI or Direct Injection engines. Now just because there is a Turbo on an IDI engine does not make it a TDI. It makes it a Turbo Diesel IDI. These were offered throughout the Mk1 and Mk2 generations.

Nonetheless! It is a snazzy looking build!  :P Congrats

Reply #2May 02, 2010, 08:57:02 pm

81 vw pu

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Re: My 81 vw pu 1.6 na to td build
« Reply #2 on: May 02, 2010, 08:57:02 pm »
Thanks 8v, but i never stated i was building a tdi. I'm using the intake, exhaust, and turbo from a tdi on my 1.6 na to build a 1.6 td.
81 vw caddy converted from 1.7 gasser to 1.6 NA. Diesel W/ FF 5 speed.
1.6 TD intake and exhaust w/k14 turbo,intercooled, 2.5" straight pipe. NA. pump with govenor Mod and a 50 shot of nitrous!!!

Best 1/4 mile pass= 16.8 @ 85 mph

2003 TDI Golf  1.9 ALH 2.5" catless downpipe, EGR delete

Reply #3May 02, 2010, 09:16:51 pm

truckoSaurus08

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Re: My 81 vw pu 1.6 na to td build
« Reply #3 on: May 02, 2010, 09:16:51 pm »
At first I thought the same, but after reading some more I saw what you meant.
So whats the reasoning behind this set up? Will it clear the engine bay when you install it?
Also, in case you did not know,(you probably do) you should be careful on running a turbo on a N/a engine.
Oh yeah and I heard the intake ports on a TDi dont match the ports on an IdI.

Reply #4May 02, 2010, 09:22:40 pm

VW Smokr

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Re: My 81 vw pu 1.6 na to td build
« Reply #4 on: May 02, 2010, 09:22:40 pm »
Looks nice, 81 vw pu. Looking forward to hearing how it fits & performs in your truck.

Planning on installing an intercooler?

J.R.
SoCal

Reply #5May 02, 2010, 09:32:06 pm

8v-of-fury

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Re: My 81 vw pu 1.6 na to td build
« Reply #5 on: May 02, 2010, 09:32:06 pm »
Thanks 8v, but i never stated i was building a tdi. I'm using the intake, exhaust, and turbo from a tdi on my 1.6 na to build a 1.6 td.

well don't I feel stoopid ;) my bad broski. Is the turbo a Prothe piece too?

Reply #6May 02, 2010, 11:04:27 pm

81 vw pu

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Re: My 81 vw pu 1.6 na to td build
« Reply #6 on: May 02, 2010, 11:04:27 pm »
The reason i went with this set up is from what i understand it only produces about 10 psi boost. That about what i'm looking for. I dont see any clearence issues yet, but i am going to have to extend that short downpipe and go over to the passenger side a little more. Yes the intake ports are different. The tdi intake has a D shaped port, and i'm trying to decide which gasket to use. Both gaskets cover the intake ports, but i like the na gasket better. I'm not installing a intercooler, just a hot pipe for now. I may turn fueling up a bit but not till my egt guage is installed. And yes 8v the intake, exaust manifold, turbo and downpipe are a kit i bought on e-bay from Proth.

 

Here are a few pics of the tdi intake and 1.6 na head ports.

tdi  D port intake

tdi intake with 1.6 na gasket

tdi gasket on 1.6 na head

another view of tdi gaskets on 1.6 na head
81 vw caddy converted from 1.7 gasser to 1.6 NA. Diesel W/ FF 5 speed.
1.6 TD intake and exhaust w/k14 turbo,intercooled, 2.5" straight pipe. NA. pump with govenor Mod and a 50 shot of nitrous!!!

Best 1/4 mile pass= 16.8 @ 85 mph

2003 TDI Golf  1.9 ALH 2.5" catless downpipe, EGR delete

Reply #7May 08, 2010, 12:42:13 am

81 vw pu

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Re: My 81 vw pu 1.6 na to td build
« Reply #7 on: May 08, 2010, 12:42:13 am »
Well I did the turbo install today and got to drive it tonight. I still have to fab a better downpipe
as the one that came with the kit is in the way of the relay shaft in 2nd and 4th gear.
here are a few pics of the progress.

Everything taken apart, ready to go back together.

Exhaust manifold and turbo bolted on.


TDI intake bolted on.


Drilled and tapped oil filter adapter for 1/8 pipe x -4an fitting.


Hot pipe from turbo to intake installed.

Oil return line installed.



81 vw caddy converted from 1.7 gasser to 1.6 NA. Diesel W/ FF 5 speed.
1.6 TD intake and exhaust w/k14 turbo,intercooled, 2.5" straight pipe. NA. pump with govenor Mod and a 50 shot of nitrous!!!

Best 1/4 mile pass= 16.8 @ 85 mph

2003 TDI Golf  1.9 ALH 2.5" catless downpipe, EGR delete

Reply #8May 08, 2010, 01:29:16 am

81 vw pu

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Re: My 81 vw pu 1.6 na to td build
« Reply #8 on: May 08, 2010, 01:29:16 am »
Why didn't you use a 1.6TD manifold? 

These parts came in a kit I got from proth. I got the kit over a year ago, long before I
found this forum.
81 vw caddy converted from 1.7 gasser to 1.6 NA. Diesel W/ FF 5 speed.
1.6 TD intake and exhaust w/k14 turbo,intercooled, 2.5" straight pipe. NA. pump with govenor Mod and a 50 shot of nitrous!!!

Best 1/4 mile pass= 16.8 @ 85 mph

2003 TDI Golf  1.9 ALH 2.5" catless downpipe, EGR delete

Reply #9May 08, 2010, 02:44:16 am

truckoSaurus08

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Re: My 81 vw pu 1.6 na to td build
« Reply #9 on: May 08, 2010, 02:44:16 am »
How much was the kit? Interested to see how it will turn out, especially it being a turbo from prothe, from witch i've heard a few bad things. Let us know how it runs and good luck with your project.
Nice caddy by the way.  8)

Reply #10May 08, 2010, 03:08:25 am

81 vw pu

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Re: My 81 vw pu 1.6 na to td build
« Reply #10 on: May 08, 2010, 03:08:25 am »
Why didn't you use a 1.6TD manifold Interested to see how it will turn out, especially it being a turbo from prothe, from witch i've heard a few bad things. Let us know how it runs and good luck with your project.
Nice caddy by the way.  8)

The kit was $450.00, but I think they went up a bit. I got a cheaper price on one of his store sites than on his e-bay ad. I did my first burnout tonight with this caddy so I know its got more power.
81 vw caddy converted from 1.7 gasser to 1.6 NA. Diesel W/ FF 5 speed.
1.6 TD intake and exhaust w/k14 turbo,intercooled, 2.5" straight pipe. NA. pump with govenor Mod and a 50 shot of nitrous!!!

Best 1/4 mile pass= 16.8 @ 85 mph

2003 TDI Golf  1.9 ALH 2.5" catless downpipe, EGR delete

Reply #11May 09, 2010, 12:32:20 am

fatmobile

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Re: My 81 vw pu 1.6 na to td build
« Reply #11 on: May 09, 2010, 12:32:20 am »
The 1.6TD manifold is lame too.
 Good thing about this turbo is all that room above it.
You can use a cheap gasser intake that doesn't favor the center cylinders.






Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #12May 09, 2010, 06:42:32 pm

truckoSaurus08

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Re: My 81 vw pu 1.6 na to td build
« Reply #12 on: May 09, 2010, 06:42:32 pm »
How about one of those pd 150 manifolds? I think thats what they are called.

Reply #13May 09, 2010, 08:45:29 pm

GEE-BEE

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Re: My 81 vw pu 1.6 na to td build
« Reply #13 on: May 09, 2010, 08:45:29 pm »
I have a 1Y intake that might will work....

With the intake tube and a air filter assy , better than that funky hose assy

GB

1.9 AAZ, CHD 5spd with Peloquin
KO4/KO3 Hybrid turbo
Giles Pump OHC
Complete Techtonics 2'5 S/S DP and Exhaust
Coilovers, MKII Pedal Swap,G60 BRAKES
MK1 JETTA DASH
675MM 16V radiator (MKII) PASSAT DUAL FAN
42K original miles , South African Front End
15x6 Le Casletts 195-45-15

Reply #14May 09, 2010, 09:43:56 pm

81 vw pu

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Re: My 81 vw pu 1.6 na to td build
« Reply #14 on: May 09, 2010, 09:43:56 pm »
Well I put about 60 miles on the TD caddy today. Its like driving a completely different pu. Its running about 2-3 lbs boost at 55 in 5th gear, about 5-7 with 3/4 throttle, and the most I saw was 11 lbs at wot. I noticed that the factory temp guage seem to run about 1 line cooler also. It really gets up to speed faster. Took it up a couple of hills and could gain speed instead of loosing now. Im very happy with the way it turned out, but like most of you, it will never be completely finished, theres always bigger and better parts. Thanks everyone and I'll keep you updated on any changes, (good or bad).
81 vw caddy converted from 1.7 gasser to 1.6 NA. Diesel W/ FF 5 speed.
1.6 TD intake and exhaust w/k14 turbo,intercooled, 2.5" straight pipe. NA. pump with govenor Mod and a 50 shot of nitrous!!!

Best 1/4 mile pass= 16.8 @ 85 mph

2003 TDI Golf  1.9 ALH 2.5" catless downpipe, EGR delete

 

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