My Mk2 from 1.6D to 1.6TD - page 1 - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• My Mk2 from 1.6D to 1.6TD by osti on 27 Aug, 2011 08:09
• Ok it's been a while since I registered and was only reading so I think its time to post something about my car. It started life as a 1.6 Diesel. But when I got my hands on it was not enough to make a safe overtake and decided it needs a little extra boost. And I bought a KKK K24. I'll let the pictures speak instead of me.
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  In the first few days I had to drive it only with the downpipe and no silencers and the sound was fenomenal. The interesting thing was that only with the downpipe the pressure was 0.65 Bar which is around 9.4 PSi but with all the pipes from the exhaust system connected the pressure dropped to 0.5 - 0.55 Bar (7 to 8 PSI) guess the backpressure takes its toll . But I'm happy with it for now.
  
  So far the car has a Golf Mk3 GT rear axle with disc brakes and front Sway Bar from Mk3 GTI.
• #1 by CRSMP5 on 27 Aug, 2011 08:55
• silicone bad thing for those areas you used it... gaskets much better..
  
  so you used copper for the oil line??
• #2 by Blocksmith on 27 Aug, 2011 11:38
• I'm in the process of doing precisely the same thing, and noticed you used a 1.9 intake mani; did you grind out the head to fit those d-shaped ports, or just go with it as it was?
• #3 by R.O.R-2.0 on 27 Aug, 2011 12:02
•    he did use silicone in the wrong areas.. i would get gaskets in there ASAP.. silicone is more of a gasket helper, not a gasket all on its own..
  
  he also DID use an AAZ intake mani.. not so good on a 1.6 head. really not that good of a manifold at all in general.. the AAZ manifold makes lots of turbulence when bolted to a 1.6 head..
  
    he did use copper for a oil line    that bugger is gonna crack and leave you stranded, or trash your engine..
  
  you should get a proper VW oil line.. there cheap, and wont crack from all the vibrations of the diesel engine.. that copper could be used as a temporary line, but it will break eventually. no saying how long it will be, but it WILL BREAK. and when it breaks, its gonna dump all your oil, at a high rate of speed.. think of it.. a 1/4 opening, with 75 psi behind it.. it aint gonna be long before the engine is bone dry, and making new rattles that it never made before..
  
  and wtf is up with those heater hose extensions?
• #4 by nathan_b on 27 Aug, 2011 12:07
• well, buy a gasket with a windage tray for your oil pan, and you can pick all that silicone out of your oil pickup when you remove the pan.
  
  Also, way too much sealant for the intake, and you had a gasket next to it, it's fine to reuse those gaskets too..
  
  but engine looks nice, also, turn that 8 into 18 psi and you'll see why we turbo these suckers.
• #5 by osti on 27 Aug, 2011 13:18
• There were new gaskets on all parts I just havent shot them in the pictures and the silicone is used to help the gaskets. As for the copper line yeah I know what happens that was what I had left around in the garage, it will be changed soon. As for the intake manifold I did not had to grind anything except for the back of the manifold since the compressor housing was touching the manifold. And the intake manifold is from a 1.6TD not AAZ or at least that's what the man from who I bought it said.
  
  After that said I'm thinking of putting a oil cooling system from Alfa 155 8v these come with a oil thermostat and bolts almost with no modifications on the stock VW oil console.
  
  And the boost will soon be upped but for now there are other things to sort out. I'm looking for a air box out of SB but with no luck so far.
  
  
  Oh and the heater hose extensions have been put in there just for temporary usage as I said there are a lot of things to sort out. 
• #6 by nathan_b on 27 Aug, 2011 13:31
• It is absolutely a 1.9 manifold.
  
  that's why you had to grind it..
  
  But I dont think it would affect you  TOO badly.
• #7 by R.O.R-2.0 on 27 Aug, 2011 13:40
• Quote from: nathan_b on 27 Aug, 2011 13:31

  It is absolutely a 1.9 manifold.
  
  that's why you had to grind it..
  
  But I dont think it would affect you  TOO badly.
  

  
  yup.. its definitely a 1.9 manifold.. look at the ports on it. there a different shape from the ports in your head.. the intake has D ports, the head has O ports..
  
  we were NOT kidding, that DEFINITELY IS a 1.9/AAZ intake manifold.. they appear to be identical if you are ignorant of the differences.
  
  it might not make much of a difference now, but if you ever want to build your engine for power, and longevity, that manifold would be one of the first things i changed.
• #8 by osti on 29 Aug, 2011 13:50
• Damn I'm stupid I've been reading so much about the differences and havent saw the obvious oh well I'll look for another one.
• #9 by regcheeseman on 30 Aug, 2011 09:09
• Quote

  .. that copper could be used as a temporary line, but it will break eventually. no saying how long it will be, but it WILL BREAK. and when it breaks, its gonna dump all your oil, at a high rate of speed..

  
  
  I wouldn't worry about it, there is so much cowboy gasket in that engine it'll destroy itself on oil starvation first.
  
  Jeez - if you must use it, a light SMEAR.
• #10 by R.O.R-2.0 on 30 Aug, 2011 11:29
• LMFAO.. cowboy gasket..
  
  thats a good one..
  
  yes, the silicone that squishes out of the joint, that stuff will fall off if it is actually inside of the crank case.. then the oil pump will suck it up.
• #11 by osti on 01 Sep, 2011 12:40
• No worries the whole engine is being torn apart for a complete rebuild.
• #12 by osti on 01 Sep, 2011 12:51
• Quote from: regcheeseman on 30 Aug, 2011 09:09

  Quote

  .. that copper could be used as a temporary line, but it will break eventually. no saying how long it will be, but it WILL BREAK. and when it breaks, its gonna dump all your oil, at a high rate of speed..

  
  
  I wouldn't worry about it, there is so much cowboy gasket in that engine it'll destroy itself on oil starvation first.
  
  Jeez - if you must use it, a light SMEAR.
  

  
  I'm sorry but do you even know how to use silicone? I don't want to start a fight but that silicone has to be there and don't worry it did not fell in the oil sump or got sucked in the engine. Cheers! 
• #13 by rallydiesel on 01 Sep, 2011 13:20
• I'm afraid to ask, but what did you use for the oil drain line?
• #14 by wdkingery on 01 Sep, 2011 13:39
• damn these guys are beatin on you like a red headed step child..
  don't worry about the silicone.. i put more than that every time i've done an oil pan (many, many fords) and i've never had one come back locked up.