1.5/1.6 Hybrid

[RustyCaddy]

The head gasket will be the fuse I'd guess..  Are you running with head studs?  I have 1.6 internals with a 1.5 block and head (don't ask, long story)

i do wonder about the details of the 1.6 internals in a 1.5l?

Yeah, the engine has headstuds so it might hold up awhile; i think i will keep boost low at 10-12 psi

Zukiman87: please do post your build progress!

[maxfax]

i do wonder about the details of the 1.6 internals in a 1.5l?

I guess the story isn't all that interesting..  I bought an '81 Rabbit with a cracked head.. The PO had gotten a freebie engine with a trashed crank and yanked the head and had it completely refurbished..  After yanking the engine from the Rabbit and tearing it apart with intentions of replacing all the rings and bearings he found the block was cracked so he decided to use the other block he had gotten which was amazingly not cracked..  While assembling the bottom end he found that the rods were hitting at the base of the cylinder bores and at the oil pump land..  He couldn;t figure out the issue, got frustrated, and sold the whole lot (new piston rings, bearings, oil pump refurbed head, bottom end gaskets, timing belt, tensioner) for 100 bones, to me  ..

Since everything was cleaned up and this far along (and this car was just for a daily beater WVO car) I opted to do some grinder therapy to the block and run it..   Where I went wrong was I cheaped out and used the friggen stock head bolts.. The rest of the story is here http://www.vwdiesel.net/forum/index.php?topic=22403.0

[VW Smokr]

The head gasket will be the fuse I'd guess..  Are you running with head studs?  I have 1.6 internals with a 1.5 block and head (don't ask, long story)

i do wonder about the details of the 1.6 internals in a 1.5l?

Yeah, the engine has headstuds so it might hold up awhile; i think i will keep boost low at 10-12 psi

Zukiman87: please do post your build progress!

x2 here, on a similar "1.6 internals in a 1.5l" hybrid currently in project status; it's a new(!) 1.5 block, but it's clearanced for the 1.6 crank's throws and set up with piston squirters, with rotating assy re-balanced. Looking for the head studs (Yes, mandatory for 1.5 block), high volume oil pump, thermal barrier coatings, and intercooler to add longevity while staying in the 10-12psi boost range for fuel efficient travels.


J.R.
SoCal

[Zukiman87]

Next question. Can I just use the 1.6 rod crank and main bearings? They're cheap and probably easier to find.

[R.O.R-2.0]

it will be interesting to see how quickly a k14 turbo with low boost will blow up my engine

The head gasket will be the fuse I'd guess..  Are you running with head studs?

I have 1.6 internals with a 1.5 block and head (don't ask, long story).. Managed to get about 150K miles out of it till (surprise surprise) the block cracked, then I ran it about another 50K (more story).. ..     The mileage indeed was indeed a tad low..  Peak was about 47mpg with darned good behavior.. Average was usually around 36-40 pending on weather and the driving habits for that week...  But darn did it start good..

i cracked the block first i think.. but the head gasket still had chunks missing.. and this was on a 1.5 with OVER 35psi boost.

[R.O.R-2.0]

The head gasket will be the fuse I'd guess..  Are you running with head studs?  I have 1.6 internals with a 1.5 block and head (don't ask, long story)

i do wonder about the details of the 1.6 internals in a 1.5l?

Yeah, the engine has headstuds so it might hold up awhile; i think i will keep boost low at 10-12 psi

Zukiman87: please do post your build progress!

x2 here, on a similar "1.6 internals in a 1.5l" hybrid currently in project status; it's a new(!) 1.5 block, but it's clearanced for the 1.6 crank's throws and set up with piston squirters, with rotating assy re-balanced. Looking for the head studs (Yes, mandatory for 1.5 block), high volume oil pump, thermal barrier coatings, and intercooler to add longevity while staying in the 10-12psi boost range for fuel efficient travels.


J.R.
SoCal

he wants 1.5 internals in a 1.6 block guys, not the other way around.. the 1.5 parts will require no grinding when dropped in the 1.6 block..

and if your gonna have head studs on anything, just run a load of boost. or if you aint gonna run much boost, dont waste the money on studs..

i ran up to 30 psi to a STOCK 1.5D for almost a year before i finally cracked the block BAD (7 head bolt holes had cracks)

[RustyCaddy]

he wants 1.5 internals in a 1.6 block guys, not the other way around..

Your right about that...thanks for getting back to the subject.

But Maxfax does have a couple of great threads there 

i picked up a new set of ARP head studs for $65.00 shipped so it was 'an offer i could not refuse"

Got a 30 year old set of German Mahle 0.5mm overs than i want to use someday in a 1.6 hydro block; new 1.5 cranks are still available and cheap so the OP will have some good info; very cool

[maxfax]

Next question. Can I just use the 1.6 rod crank and main bearings? They're cheap and probably easier to find.

The 1.5 has smaller rod bearings IIRC, mains are the same though... 

Head studs are priceless on any 11mm 1.5 or 1.6.. I can't say that enough!     It's a requirement on a turbo application, and might as well be on a NA.. 

Zuki, to get back on the original topic and to recap a bit..   You plans of right now are to use the 1.5 rotating assembly and minty 1.5 head with a later 12mm 1.6 block, correct?

[maxfax]

i picked up a new set of ARP head studs for $65.00 shipped so it was 'an offer i could not refuse"

THIEVERY!!!!   

[RustyCaddy]

THIEVERY!!!!   

 

[Zukiman87]

Correct!!

[maxfax]

Cool..  Have you read though the link I posted about swapping heads around? All the poop should be there about swapping the 1.5 head on that block..  You'll need to use the 1.5 rod bearings and head gasket, as well as the little adapter doo hickey.. Everything else should be pretty straight forward.. 

AS far as the injection pump, you have any plans on what you'll be using there yet? There are some slight differences between the 1.5 and 1.6 pumps..  Not sure exactly what, I think most of it is timing and governor.. (maybe Burn_Your_Money can chime in here) AS far as interchanging a 1.6 pump on a 1.5 and visa versa I've never really been able to tell much difference..  You can swap the top from a TD pump onto the 1.5 pump...

[fatmobile]

How about the prechambers?
 Difference between the 1.5 and 1.6 prechamber volumes that might effect compression?

[Zukiman87]

I read the link thanks. Good stuff in there. Anyone have a pic of a ported head?

I'm trying to make up a list for what I'll need to rebuild the bottom end while it's out. Don't want to screw anything up. As far as the top end goes head studs and the metal gasket are a given.

With injector pump I'll use the old one and put a turbo top on it. It's going to get tore down and a full rebuild anyways. Probably do the governor too.

Vnt-17 turbo and as big of an exhaust I can fit.

Should be good!

[maxfax]

Sounds pretty much like you got all your proverbial ducks in a row...

How about the prechambers?
 Difference between the 1.5 and 1.6 prechamber volumes that might effect compression?

He's still using a 1.5 head on a 1.5 rotating assembly..  Compression will remain the same..