85 IDI Rebuild

[silentdub]

Hey guys, I am about to tear down this 1.6 for a rebuild. It has a broken timing belt, so it needs to come apart.

I am looking to make this engine as efficient as possible, if you guys have any tips tricks or sticks, I would love to hear any and all ideas so that I can pass them off as my own.


I already have a tubular exhaust manifold for it and will probably run 2.5 inch TT exhaust since that is already on the car and is new, but I'll change/try anything.

[R.O.R-2.0]

where did you find a tubular manifold?

all the ones ive found so far are either cast iron, or stamped steel..

[silentdub]

where did you find a tubular manifold?

all the ones ive found so far are either cast iron, or stamped steel..

Tubular from an MKIV 2.0, they used the tube style similar to the header. I am not sure if it will bolt up, but that is why I have cutters and welders.

[R.O.R-2.0]

where did you find a tubular manifold?

all the ones ive found so far are either cast iron, or stamped steel..

Tubular from an MKIV 2.0, they used the tube style similar to the header. I am not sure if it will bolt up, but that is why I have cutters and welders.

are you sure you arent talking about the stamped stainless steel mk4 mani? the mk4 manis wont bolt up without modification to the flange.. try bolting it up, you will know what i mean..

[silentdub]

If you wanna called it stamped then that is what it is. It's been sitting on an old 2.0 I one had, I figure it could be cut and with some modification, it will bolt up.

I haven't pulled the 1.6 apart yet, this will actually be my 1st diesel motor, so this is all new to me.

[R.O.R-2.0]

If you wanna called it stamped then that is what it is. It's been sitting on an old 2.0 I one had, I figure it could be cut and with some modification, it will bolt up.

I haven't pulled the 1.6 apart yet, this will actually be my 1st diesel motor, so this is all new to me.

well, theres a cast manifold, and its well, cast iron.. pretty self explanatory..

then there is another manifold.. it is made out of 2 pieces of stainless steel stamped together.. there is nothing tubular about it that i can see.. unless the stainless is just a heat shield, and there are INDEED tubes inside there..

yes, they will work if modified..

[CRSMP5]

tt sells a very $$$$$ downpipe for mk2-4 style manifolds... they include a modded shiftlever which is what gets in the way... id copy that vs modding the manifold..

[R.O.R-2.0]

tt sells a very $$$$$ downpipe for mk2-4 style manifolds... they include a modded shiftlever which is what gets in the way... id copy that vs modding the manifold..

oh yes, i forgot about that! its gonna be impossible to get a mk2-4 downpipe on a mk1..

[keaton]

picture is worth a 1,000 words....

[maxfax]

I'm guessing this is a NA engine..   Keep this in mind if it looks like you'll be getting into a lot of modifying to get that manifold you have to work, the stock "toilet bowl" manifold will flow more than enough for a NA 1.6..  The restriction is everything from the factory connected to the manifold back... Typically opening everything up to about 2" to 2.25" using the stock toilet bowl stuff will do just fine...

AS far as efficiency..  Your right foot and gearing are the big players here..  Proper timing and a fuel system in good order (especially injectors) are next on the list.. 

Pertaining to the base engine whatnot it's the same as if you'd be building a tree fidy Chebby..  Proper tolerances, good seal on the rings and valves etc etc and you're golden..  Some have machined the IM shaft to take some weight off, never really heard if there were any noticeable gains to be had or not.. Bang for the buck would be a Giles Super Pump, but you'll need a couple bucks for that..

 

[silentdub]

The timing belt broke on this motor prior to me getting it, so it will be a full rebuild for the most part. No big deal really.

The exhaust can be figured out even of I have to get some bent pipe and weld it, no big deal there, it's just a pipe to carry exhaust.

Gearing is one thing that I am looking at. I have a few good gear boxes in the garage, I also have one blown gear box with a .71 5th, so you know where that is going

I'll choose the one with the lowest final drive. I'll run a 1,2,3rd  gear that will give me some get up and go from a stop.

60% of the fuel used at speeds above 40mph is fighting wind resistance. I'll have to work on this a little too. I know that there are some mods that I can do but will probably choose not to since it will make the thing look ugly. There are some things that all of us can do though.

Blank off the grills up front, lower the car, full belly pan, diffusers on the rear roof, flat wheel covers with no holes.

The other mods may make the car just look freaky.