Porting 1.6 head to suit PD intake

[Hiho]

Hi all,

I'm considering using a PD intake manifold on my 1.6TD motor and porting the head to match the manifold. Has anyone done this or would advise not to?

My other consideration is a 1.9 head and PD manifold on my 1.6TD however my motor is mech... Would this conversion be worth the trouble in terms of performance gains?

Cheers!

[RabbitJockey]

i'd be pretty scared to cut a 1.6 head that much, aaz head is a good option, you only have to plug one hole on an aaz head to use it on a mechanical lifter block

[theman53]

You don't have to do anything with the lifters? If that is the case I may send my aaz head out for bigger valves and let it rip.

[Hiho]

so the 3mm difference in bore diameter is not an issue for the 1.9 to 1.6 swap? Do the 1.9 heads flow much better?

[Alcaid]

so the 3mm difference in bore diameter is not an issue for the 1.9 to 1.6 swap?

No, not an issue as the heads are completely flat so there isn't any "bore" in the heads.

The AAZ heads have 2mm bigger intake valves and ports are supposed to flow better. Word of warning though, you lower the compression by putting on the AAZ head so cold start will suffer. Timing needs experimenting as well.

[theman53]

http://www.vwdiesel.net/forum/index.php?topic=15780.0

A link to saurkraut's making a mech 1.9 aaz head. Aparently you do not have to change anything to run hydro on a mech block, unless you want to. Hmmm

[nathan_b]

so the 3mm difference in bore diameter is not an issue for the 1.9 to 1.6 swap?

No, not an issue as the heads are completely flat so there isn't any "bore" in the heads.

The AAZ heads have 2mm bigger intake valves and ports are supposed to flow better. Word of warning though, you lower the compression by putting on the AAZ head so cold start will suffer. Timing needs experimenting as well.

Cold start problems is a myth that needs to die.
Mine started with one glow, no block heater at -12f last winter.

The reason that cold starting is an issue is when people want to lower compression more, and use the wrong headgasket for piston protrusion.

[RabbitJockey]

so the 3mm difference in bore diameter is not an issue for the 1.9 to 1.6 swap?

No, not an issue as the heads are completely flat so there isn't any "bore" in the heads.

The AAZ heads have 2mm bigger intake valves and ports are supposed to flow better. Word of warning though, you lower the compression by putting on the AAZ head so cold start will suffer. Timing needs experimenting as well.

Cold start problems is a myth that needs to die.
Mine started with one glow, no block heater at -12f last winter.

The reason that cold starting is an issue is when people want to lower compression more, and use the wrong headgasket for piston protrusion.

also someone had built a franken engine with a head that had bent valves, that didn't help to kill the myth haha.
.
u can just block the extra oil drain hole and run the 1.9 head as a hydraulic head, it doesn't need to be converted to solid lifters.  just make sure u have the later oil pump  u also need to run the machanical lifter headgasket

[R.O.R-2.0]

an AAZ head on a 1.5 will probably not start that great tho.. thats what we were saying would not start great..

apparently the 1.6's do fine tho..

[Hiho]

I have that problem with my 1.6td. Below -5C she wont start with the starter. Its downhill all the way into town though.....
I suspect the head gasket is too thick for the piston protrusion...... Fortunately -5c only happens a couple of times each year here but I'd like to address the head gasket to achieve the proper squish/quench arrangement (and use a 1.9 head to lower compression)

so I have some options.....

Stick with the stock manifold
use a PD manifold and port the 1.6 head to match
buy a second hand AAZ head and use a PD manifold
buy this Prothe head: http://www.hansautoparts.com/AAZCompleteHead.htm and use a PD manifold

as a minimum I will have to replace the head gasket with the correct thickness (might go metal with arp studs while im at it)

I like the idea of the car looking relatively stock (from a policemans perspective) so no pod filter etc.... I will use a VW/Audi/Seat air filter box. The only trouble will be making the intercooler pipework look factory. "Officer, I swear all Mk1 golf diesels have intercoolers rated to 350hp"

My girl has bought a 2009 Polo 1.9TDI so our Mk1 TD will no longer be a daily driver......... I'm a bit sad about this but it means that I can take it off the road and really sort it out!