All, Just trying to get a compilation of all the somewhat simple mods to do for a 1.6L IDI. If I have left something off, please let me know. I do not necessarily plan on doing all of these, but these are mods that have been discussed for the 1.6L IDI that I may consider.Turbo:Early TDI turbo - might be a little small.. a VNT would be betterIntercoolerInstall squirters - not needed unless you are holding it at like 1200* egt for a very long time.. ask me how i know.Fuel Pump:Governor mainspring mod (shimmed)Fuel pin mod (trimmed) - only needed on a n/a pumpSmoke screw adjustmentFuel pin plastic washer trimming - only needed on a TD pump topTiming piston cut down - theres an easier way.Timing piston cover (spring side) ground down - why?Shim under plunger foot (I have no idea what this is) - again, why?10mm pump head upgrade - again, why1.9L camplate and plungers - same..155bar injectors due to turbo upgrade but which ones? the plunger spacer, plunger, pump head, and cam plate are basically matched up to operate properly..and you really dont need 155 bar injectors.. im running fresh 135 bar injectors in my engine.and Dave Cross was building right around 200 hp with a stock pump head and injectors..as for the advance piston/cover mods, theres a much easier way to do this. just install a TDI advance spring cover.Valves: - Install AAZ head and be done with it.34mm intake (stock) to 36mm (Audi 500s)31mm exhaust (stock) to 33mm (VW aircooled cut down)Does anyone know of anyone who has done this? Where did they get it done? Cam: - Dr Diesel and Giles make cams..Colt Cams is the only one I have read still producingBlock:Girdle (this means no crank scraper or windage tray due to interference)Upgraded rods (Rostenís is building some for $450 Euro / set), unless someone knows of a better price from Scat, Pauter or Crower) ARPs on rods, headFront of crank mod to TDI serpentineOil pump upgrade to 36mmBalance engine - not super necessary, since our engines only turn a limited number of RPMs.. 5600 is about all you can get out of these.Total Seal gapless ringsHead:Port and polish - intake side is alright, the exhaust ports are what really need opened up3 angle valve job(Are the factory valve spring good enough? If not, replace with what?) - dont need much better valve springs, these engines wont run enough boost, or turn enough rpms..O-ring the head (Who does this for VW heads and where online can I get the o-rings?) - never seen or heard of getting a VW o-ringed, and i dont think it would do much good, because the head is the weak spot. it actually flexes when theres lots of boost. o-rings are not going to fix this issue. or else you pull the head studs right out of the block, again, o-rings wouldnt fix that.Thanks a lot. Just trolling for ideas on a 1.6L N/A into a 1993 Geo Tracker 2 door 4x4 with an Acme Adapters conversion kit. I already have the 1.6 N/A block before anyone suggests a 1.6L TD or a 1.9 TDI!
Max, the 135bar injectors have been shown to result in *better* fuel economy. The 15bar injectors reduce smoke. My explanation is that the fuel squirted at 135bar requires less drag on the engine than the same amount of fuel squirted at 155bar, but the fuel squirted at the higher pressure is more atomized and so burns more cleanly. The increased efficiency of the cleaner burn doesn't offset the extra energy required to squirt at the higher pressure.
The high pressure portion of the injection pump is exactly the same between the N/A pump and the TD pump. You need to match the timing spec to the type of injectors, but not the pump to the injectors.
All, Thanks for the input. ROR....My intent is not to build a hot rod. I am just trying to see what all mods are available and out there, get feedback about each one, and then decide on which ones to do. Remember, I never said I was going to do any or all of them. As far as your input....some clarification please:early TDI turbo....you suggest a VNT, how can I run a VNT turbo without electronics to actuate it? Vacuum, boost?squirters.....These I will install. This is my wife's daily driver as well as our weekend fun truck and I cannot guarantee she will not run it hot on her watch. She has alreay run a 4.3 Chevy van through water and hydrolocked it. So, this is insurance...and a way to save me mechanic time!Pump mods:I have no idea why half of these mods are...that is why I am asking?!?! They are not my posts...I have just read of people doing them.Nice to know about the injector pressure. Have you tried 155s to see what it would do? I will be going from a NA pump to TD so it would seem you would need to match the pump with injectors.....The advance spring cover from a TDI would save a lot of trouble. Do you have a PN? What difference is there in it an a TD?Has anyone compared the cams between Colt, Dr Diesel and Giles?And you pretty much answered the question of the oring. Never saw a parts site offering o-rings for a VW.I have heard the 5 speed trannies in the Trackers were rated higher than that. I do have 4.30s front and rear to get the RPMs down on the interstate and to offset that offroad, I have ordered the 4.24:1 transfer case gears to make it more friendly on the trails. Nothing extreme mind you.It would be nice to put a Toyo 22R in it but then my $700.00 adapter kit would be useless. I would have to buy ANOTHER $700.00 adapter kit to a 22R. Again, everyone thanks for the input and if you still have input....let me hear it.
ROR, Also, Acme does have a Bare Bones kit that adapts the 1.6L to a 22R. $425.00.
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