1.6 na Upgrades (nope, not adding turbo)

[Traktor]

OK, been lurking here for a bit and tried to find all the relevant info I can about my car but still have some unanswered questions.

- high flow manifold. One from a gasser was mentioned, would that be a straight swap or is there a specific type I need?
- exhaust. Read about a cat-back a few times, seems to be the most recommended. Where could I find one or a suitable replacement?
- timing adjustment. What exactly is required?

Anything else? All help appreciated.

[Master ACiD]

if the injectors are old or the engine has been overheated get them tested and or rebuilt. i know this seems like common sence but everyone assumes that they have good injectors when infact hardly anyone does.
a proper injector test is normally free from a bosch rebuilder so it will only cost you 4 new heat shields and a bit of time to find out what you have.

take care of the valve lash, test the compression, be sure the brakes are not dragging, wheel bearings, etc.

basically, just use common sence. these little diesels might be slow but they are not that bad when everything on the car is in good working order.

[2mAn]

OK, been lurking here for a bit and tried to find all the relevant info I can about my car but still have some unanswered questions.

- high flow manifold. One from a gasser was mentioned, would that be a straight swap or is there a specific type I need?
- exhaust. Read about a cat-back a few times, seems to be the most recommended. Where could I find one or a suitable replacement?
- timing adjustment. What exactly is required?

Anything else? All help appreciated.

ive been trying to find lil things to make a difference on my IDI motor as well. i was at the junkyard this weekend and i saw an 85 diesel golf and its intake manifold looked much better than the one on my 84 diesel jetta. it had round ports and the PCV was relocated lower in the manifold, closer to the head. my manifold has rectangular ports that dont appear very large, and the PCV puts the oil right on top of the air filter. im hoping that manifold is an improved version that was an upgrade for mk2 cars.

ive heard a 2.25" exhaust is enough for an NA car, also no cat, these are non-cataylst cars (at least mine is) so no need for a cat  

i just ordered a rebuilt injection pump from Giles at Superior Fuel in Canada and it is said to add 20whp, just about 50% more power than a stock 1.6 IDI motor. :lol:  i cant wait

[vwmike]

2.25" exhaust would likely be extreme overkill for an NA diesel. 2" ought to be more than sufficient.

[greggearhead]

The Diesel intake manifolds are restrictive compared to a gas engine's, but an NA diesel flows a lot less air.  A Gas rabbit intake mani starts to restrict around 90-100hp, I am not sure if the diesel manifold is a restriction at 50-60hp.  I flowed one once, have the figures around here somewhere.

A mild port and good valve job work wonders.  A Touch more compression also helps.  A good exhaust manifold and twin downpipe, and a mandrel bent 2" exhaust, pump timing mods and you should be pretty darned optimal I would thing.  You could always check into propane or nitrous as well.

[vwmike]

The diesel intake runners are much longer than the gas intake. Shorter runners mean lower intake velocity and possible low-end torque loss which is something to consider.

[Traktor]

Hey, thanks for all the reponse, more than I expected. Have to admit, though, most of it is over my head. More of a tinkerer than a gearhead at the moment.

So, where should I start?

[jtanguay]

start with the basics:  pump timing + timing belt change.  Check compression-do a wet test, and get the injectors checked.   If you get all of that fixed, it should run pretty sweet and start right up in the winter.  If compression is too low, consider doing a ring job.

Next step after that is some less important things like wheel bearings, alignment, brakes.. etc.   but for now start with the basics

[2mAn]

2.25" exhaust would likely be extreme overkill for an NA diesel. 2" ought to be more than sufficient.

does anyone know the OD of the factory exhausts, diesel and the gasser??