New to this Diesel stuff, is a VIN H 1.9 Turbo Diesel IDI or TDI??

[8v-of-fury]

Yeah, you can hit 100 fairly easily with the AAZ. Mind you, you do have a K03 so you're limited as far as boost goes. Maybe 15 psi tops.

K03 is good to handle 18psi reliably. It was the same model years that got the GT-15 that can only handle the 15psi.

I'd say my brothers AAZ is easily over 100bhp.

I think you are off 8v??? The 1.6L TD was 77hp wasn't it? I think that is in the bentley. Eco was 59 I think. I have no idea what it is but I think it should be around the 90hp mark as that is what the TDI's are, so probably a little lower...80something.

Where do you get your numbers? LOL.

MF - 51 kilowatts (69 PS; 68 bhp) @ 4,500 rpm; 133 newton metres (98 lbf·ft) @ 2,500 rpm
ME - 40 kilowatts (54 PS; 54 bhp) @ 4,800 rpm; 96 newton metres (71 lbf·ft) @ 2,500 rpm
AAZ - 55 kilowatts (75 PS; 74 bhp) @ 4,200 rpm; 150 newton metres (111 lbf·ft) @ 2,000 rpm
1Z/AHU - 66 kilowatts (90 PS; 89 bhp) @ 4,000 rpm; 202 newton metres (149 lbf·ft) @ 1,900 rpm

[CrazyAndy]

I figure if the engine is too far gone I at least have a usable trans, and shouldn't the trans work just as well for a TDI? There shouldn't really be any difference trans wise between the two types of engine.

And as far as horsepower, 100hp (+ some change, I think it was 102 or 103 hp actually) sound right for a 1996 IDI engine?

Depends on your trans code.  Find it on the bell housing of your transmission.  Go to this site:
http://zelek.com/diagram_charts/diagramlist.htm
Go through that list and determine your trans' gear ratios.  Once you have that, go here:
http://www.scirocco.org/gears/
Input your current tire size into the fields provided.  If you want to find your cruising speed, use your 5th gear ratio and specify your desired speed.

The trans will work with a TDI, but revs might be a little higher than a comparable TDI since the IDI's tend to be a little more efficient near the midrange.  The only way to find out for sure is to determine your trans code.

And 8vOF is close; stock AAZ power figures are 75 HP @ 4500 RPM and 114 ft.lbs. at 2500 RPM.  The ABA 2.0 gas motor is the only thing i can think of coming close to 100HP stock, and they only had 90-94 HP stock.

The AAZ is a solid engine minus crank concerns, and will serve you reliably in you Jetta.  Adding an intercooler, installing larger diameter exhaust system from the downpipe back, and modifying your fuel injection pump and boost levels can and will see you beyond 100HP on the stock internals.  I'd pick up head studs if you plan on going added power, to be on the safe side. 

That's NOT knocking the awesomeness of a M-TDI AZU/1Z, but you've got yourself a solid base already, if the head and pistons haven't done too much damage to themselves.  Do what  R.O.R. and  burn_your_money say, and dissemble the engine, fixing the crank sprocket concern as well as refurbing the valves/pistons if necessary.

Sorry for the long-winded take on things, just had a lot of thoughts on this.

Good luck!

[burn_your_money]

K03 is good to handle 18psi reliably. It was the same model years that got the GT-15 that can only handle the 15psi.

Are you talking about the TDI turbos? AAZs didn't get a GT-15

[8v-of-fury]

Whoops, yes I was. So yeah the k03 is good to 18psi lol

[rmcard]

Me thinks a 100hp rabbit pickup will do just fine.  I do see you can get new Turbocharger upgrades on ebay for reasonable prices but would I really want to put the engine under extra heat and stress by messing with the turbo?

Not having any experience driving one all I think I'm looking for is the little thang having some guts out on the highway if I want to pass someone or hualing something heavy in the back.  Plus I can see doing some traveling out west in some of the mountain regions too.

What I am used to tho' is my daily driver Altima V6, when I stomp on it, it goes!

[TylerDurden]

Decoding this vehicles VIN I see that the 1996 Jetta was only rated in the low to mid 30's for mpg. ...
I plan on giving the Caddy a couple extra inches of ground clearance so I can run taller tires (175/70 R14's that I have), between that, the trucks light weight and driving it gentle most of the time I was hoping to get somewhere in the mid to high 40's for mpg.

I had a 1.6 in my 5spd Caddy with tall tires & bad rings... I regularly got 50mpg on the highway. The trucks are very light.

The 5spd Dasher wagon I am driving has 180/80R 13s - it got 52.4mpg on last weekend (350mi round-trip).

[vanbcguy]

Jezebel with her 1.6 kicks serious aZZ in just about any situation.  Once you get the hang of driving a turbo diesel you quickly realize that having peak torque in the 2K RPM range totally destroys most gassers at highway speed.  I've got a big laggy K24 - I have to worry about keeping enough RPMs to spool the turbo.  With the K03 you've got near instant boost whenever you want it, plus another 0.3L of engine on top of me!

You'll have all the power you'll need in the caddy, no problem.  18PSI is plenty - yeah, I run 20-25 or so myself, but really I can only hit that with the pedal to the floor in the upper RPM ranges, and realistically that only happens once in a blue moon.  You spend way more of your time driving around about 2K, which is pretty much the magic zone for a K03.  It's hard for me to get over 12 PSI at about 2K whereas you'll be able to max out your turbo at that speed.

[libbydiesel]

Whoops, yes I was. So yeah the k03 is good to 18psi lol

I wouldn't say the K03 is good to 18psi.  At 10 psi you can actually feel the drop in high-end power.  If someone wants to run more than 15 psi, then the K03 is not the turbo to use, especially on a 1.9. 

[burn_your_money]

Whoops, yes I was. So yeah the k03 is good to 18psi lol

I wouldn't say the K03 is good to 18psi.  At 10 psi you can actually feel the drop in high-end power.  If someone wants to run more than 15 psi, then the K03 is not the turbo to use, especially on a 1.9. 

It's basically the same turbo as in the AHU/1Zs that runs 15-18psi though isn't it?

Tyler

[R.O.R-2.0]

Whoops, yes I was. So yeah the k03 is good to 18psi lol

I wouldn't say the K03 is good to 18psi.  At 10 psi you can actually feel the drop in high-end power.  If someone wants to run more than 15 psi, then the K03 is not the turbo to use, especially on a 1.9. 

It's basically the same turbo as in the AHU/1Zs that runs 15-18psi though isn't it?

Tyler

just because it will build 18psi, does not mean it is doing it efficiently...

[burn_your_money]

It's basically the same turbo as in the AHU/1Zs that runs 15-18psi though isn't it?

just because it will build 18psi, does not mean it is doing it efficiently...

I mean from the factory. OEMs usually don't push parts outside of their designed safe zones.

[R.O.R-2.0]

It's basically the same turbo as in the AHU/1Zs that runs 15-18psi though isn't it?

just because it will build 18psi, does not mean it is doing it efficiently...

I mean from the factory. OEMs usually don't push parts outside of their designed safe zones.

whats factory? 11-12psi?

the T3 only produced ~10psi, but is good for MUCH MORE than that..

[libbydiesel]

t's basically the same turbo as in the AHU/1Zs that runs 15-18psi though isn't it?

Tyler

Cut that in half and you're pretty close.  Stock AHU/1Z max boost pressure is 0.5-0.65 bar (7.25-8.7 psi).

[burn_your_money]

t's basically the same turbo as in the AHU/1Zs that runs 15-18psi though isn't it?

Cut that in half and you're pretty close.  Stock AHU/1Z max boost pressure is 0.5-0.65 bar (7.25-8.7 psi).

Clearly I've been misinformed. Thanks for clarifying.

[libbydiesel]

With the ALH (and VNT15) they bumped up the max boost, but the AHU max boost was surprisingly low.  I believe that the low stock boost pressure is specifically because of the K03.