building my motor some questions

[mean88]

I have a 1.6 turbo diesel, shaved block, .5mm over, all new bearings and seals. I bolted a new 1.9 head on it, a tdi intake, and a t3 turbo.  Block has the new arp head studs and a metal 1.9 gasket. 

I need a new valve cover for it as the 1.9 head seals differently and i have had no luck what so ever in locating one online most are tdi not idi, suggestions? 

I also need a clutch as I feel the stock one wont hold, as I blocked my waste gate completely and my pump is turned up. I am having trouble finding the correct clutch for my application.  I use the car as a daily driver for work, but I know this monster will chew the stock clutch. Most clutches I found online dont appear the same as the stock one.

Any ideas on either?

Thanks
Ted

[mystery3]

What size is your clutch?

[mean88]

It's.a stock clutch 200mm I believe.

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For the VC gasket, try and locate one here in the (wanted/for sale) section or in the (vendor) section.

I bought mine from my local parts house. Also, if no luck, theres always the dealer.

The clutch... 200mm will do but so would the 210mm along with the 16V PP. if you want to have any spare life for further moding.

[mean88]

is there a clutch kit somewhere online that I can get a built setup?  I understand that if i go to a 210 clutch I have to re-mark TDC.  My other question is this, what engine is the pressure plate and disc from that I need for a 210 16V?(most sites show clutches with engine liters and what car they are from)  I have an AOP trans my car is a 90'.  Are most using a stock 16v clutch or what?

Thanks
Ted

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There is lots of places that give you a custom setup for clutches. Stock VW clutches are fine for you build.

I used a stock 210mm FW with an 8V gasser GTI disk with a 16V PP for better clamping force. Also, I used a VW Beattle 200mm disc that was a solid type. No problems or chatter.

As far as TDC point on the FW. The "0" is 0. If and when you do your clutch. Moc up the PP and FW to TDC on the engine and check then.

[mean88]

does this look right

http://www.techtonicstuning.com/main/index.php?main_page=product_info&products_id=344

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Perfect. Get it.

[ffgb]

That's what I have along with a lightened flywheel and I absolutely love it!  Just make sure to also get that brass bushing, the one that guides the rod from the throwout bearing to the pressure plate!

[mystery3]

Spec makes a bunch of clutch kits for vw's if you want something overkill which is how I usually prefer to do things.

http://www.specclutchsuperstore.com/lexus-aero-c-485_662.html

You may need to call them to order and make sure you're ordering the right parts.

[vanagonturbo]

Lots of good advice in here. although, I must say that I think you are assuming a lot here. Your build is not a clutch killing monster by any means. Unfortunately...

i would recommend a stock 210mm clutch kit and flywheel as was mentioned before. Also, TDC is TDC. No mistaking that one.

[mean88]

Lots of good advice in here. although, I must say that I think you are assuming a lot here. Your build is not a clutch killing monster by any means. Unfortunately...

i would recommend a stock 210mm clutch kit and flywheel as was mentioned before. Also, TDC is TDC. No mistaking that one.

I realize that, however, the clutch that I have from my car before the rebuild was slipping already when I would put it under heavy load with the stock engine, I dont expect better with more horsepower. 

Ted

[rallydiesel]

If missing the whole valve cover then I believe the casting is the same between the 1.6 and 1.9 so you could drill holes and use the 1.6 cover, which is more common.

[CRSMP5]

does it have 3 studs on the cam caps??? 1.9 should.. so aaz is what you seek..

[vanagonturbo]

If missing the whole valve cover then I believe the casting is the same between the 1.6 and 1.9 so you could drill holes and use the 1.6 cover, which is more common.

This is what I did. No problem. Used a Euro 2.0l valve cover so it was aluminium and used a rubber gasket.