I have to call somebody in OH next week about building/assembling a TD motor for me, I have a fresh honed/re-ringed TD short block and a head that needs to be welded but he assures me in email that to make it run along time (thats the plan) I should get it bored and new turbo pistons.
All of that aside what are some other things IF/when I go through with getting somebody else to build a motor for me (I have too many other projects and need to keep my diesel running every day to build my first motor and screw it up on my DD)
I plan on at least using head studs and a 1.9l metal HG, getting a 2.5" DP for the turbo which is tight ( I can change that in the future if for some unseen event it craps out) I have NA injectors with GTD nozzles and would get them switched over to TD, have a good condition TD fuel pump (2 actually), the head besides needing welded is fresh.
what else should I have done that might not be "normal" but would be worth it
oh yeah I plan to run as much boost as possible with the stock pump and IC it, also I will be burning the good grease this summer with my 2nd tank
Sethyboy,
You should definitely do new pistons if your bore is worn past spec, which can be checked with a new std compression ring and feeler guage about 5/8" from the deck. Welded head? Doesn't sound good, where is it cracked? If you find a guy who can really weld cracked heads, please tell me, I have a few. Definitely have it pressure tested whatever you do. Bottom line is make sure your internals are solid, and you should hand the machine shop a spec sheet like this
http://www.vwdieselparts.com/mspecks.jpg when it goes in so they aren't left with "generic information".
All the other stuff you are talking about doing sounds fine, if you plan on overfueling it, get a EGT guage in the manifold "before" the turbo so you can see how hot it runs, don't want to melt pistons..
Sethboy,
Didn't you just sell a 1.6lTD powered car?
months ago it had 290,000mi on it when I sold it. 84 jetta, rust on the doors and I had too many cars, also it blew alot of blue smoke (now I know it was carboned up injectors) and was leaking some oil/using some.
now I have a 85 (lol alot newer) with a ECO motor in it. and only 245k on the body, 75k on the motor.