Advise for 1.9D engine modifications.. lots of pictures

[Staley]

Hello!
I was searching TDI club and came across RedRotors username and his very knowledgable posts..
sent him an email and thankfully he replied.. and pointed me here.

My name is Mike and I own a VW/Audi shop in Houston, Texas.

I bought a 1982 Rabbit D from a guy last year and have been slowly restoring the car.  
I took the car to the chassis and painted it Jazz Blue..
and took out the worn out 1.6L Diesel.  

I bought a 1.9L D "1Y" code from a friend of mine @ Overland Parts.
and a new Bosch pump.

Everything that I do to the car is new.. so it has taken me awhile to restore.  The Rabbit is SO
much faster than the 1.6 and it is very fun to drive. I have this problem... I am a turbo freek and even installed
twin k03's on my wifes 2.8L V6 Passat. (audi s4 parts)

One of my first cars was a 80 Dasher that my folks bought new.
When I came across this Rabbit.... I just HAD to buy it ($50US) LOL

I have been researching the D to TD swap and it seems fairly simple.
Fueling/Turbocharger/Intercooler. (isn't that what everyone says)
I have been told that the 1Y is the same as the AAZ but the piston pins and rods are not as strong.
also.. the 1Y has piston oilers. also Overland uses the 1Y for their AAZ engines.

I have accumulated 3 pumps I will list the part info here

1: (new from overland) BOSCH NA   0 460 484 108  VW  068 130 109R
this is a euro pump that was for a 1.6D it has an electric cold start.

2: BOSCH TD  0 460 494 200  VW  068 494 200 (used)

3: BOSCH  NA  0 460 494 50  VW  068 130 107 AD (used)

I also have the Spearco fuel riser module that I could use.

What turbo do you recommend to use for best performance and
who on these forums can modify my pumps or sell me another one.
I have read alot of posts here about pump modification and WOW they are informative.

I bought an original 1.6D spearco addon turbo kit and a early BAE turbo kit..
I don't think that I will use them.. so they are going to be for sale once again soon..
what is the demand for old kits like that. what are they worth
(i'll post some pics)

any advice is greatly appreciated
thanks in advance
Mike Staley


here are some pictures...
BEFORE

the tailpipe was a joke




DURING







Here is the passat




here are the turbo kits





My wife thinks that I am on the computer too much now..
wait until I spend the next few days reading every english post on these forms! LOL

[Cheesetoast]

wow the before and after pics on that rabbit bring a tear to my eye.  good job man!  no help from me here, except for moral support.

[BlackTieTD]

My wife thinks that I am on the computer too much now..
wait until I spend the next few days reading every english post on these forms! LOL

welcome!  

nice rabbit. <definite feelings of jealousy>  :roll:

here you go: http://www.hostboard.com/cgi-bin/ultimatebb.cgi?ubb=forum&f=4037

..the old forum before we moved here. some good info over there..book off a good chunk of time with the boss

[fspGTD]

Wow, great looking motors - both of them.  And that Rabbit resto looks like you are having a lot of fun!  Welcome to the forum and to diesel performance.  

PS - LOVE your aftermarket boost enrichment device.  Those are really rare, I have an old magazine article that talks about them and has a black and white picture but it's hard to see details, that is the first time I've seen a really clear picture of one.  Thanks for sharing.

Also, regarding pump modification, it really is an active and ongoing area of research.  We will happily bring you up to speed on what we've found works so far and what we've tried (well first... search the forums old and new please as I'm sure you will), but don't think that we've discovered all the tricks already!  IMO, we are still in a steep part of the learning curve on figuring out what works with these engines, VE-pumps and other diesel fuel injection system performance modifications, and no one has completely uncovered all the tricks yet! (at least among those who are willing to share.)  It is an exciting time to be involved with performance-tuning these diesels, indeed.

[Staley]

I have a question about the BAE turbo kit..
this turbo does not have an internal wastegate..
is the kit missing something? Is it supposed to have an external wastegate or is it some early verson of a variable vane?
I don't think that the turbo kits are going to work for my 1.9L
I have been thinking about using the AAZ turbo.

If I want to sell these kits what are they worth?
the BAE and the Spearco.

I didn't even know that spearco made a turbo kit for the early diesel

have a great weekend!
Mike

[fspGTD]

I knew someone who ran a BAE turbokit on their late-70's VW Dasher 1.5lD.  I can verify that the kit was designed without a wastegate.  You know that was a popular way (simpler) to design turbosystems in the early 80's / late 70's.  Nowadays most turbo systems are wastegated for quicker turbo response at a lower RPM, or even variable-vane, a further step up beyond the wastegate.  A non-wastegated turbo does have advantages over wastegated, particularly it will have better power up high in the RPM area.  The kit would still make a nice upgrade for anyone with a 1.5lD or 1.6lNA.  As to pricing, I would think that a good condition, complete kit would be worth several hundred US$.

[Centurion]

Nice work ! - the first pic looked like my second set of diesel wheels -

Keep it up!

Thanks for the manual DL too! I grabbed it!

you never can have tooo much info around!