How much H.P. 1.6 turbo diesel

[Dean Erickson]

What would be the best 1.9 td to put in my truck. Best power, reliability and less electrical bull crap. Won't a 1.6 td pump fit on a 1.9? that would get rid of the electrical stuff. What year engine also.
Thanks.

[CRSMP5]

easiest best..

96-99.5 tdi from passat/jetta as its same style block set up as stock.. with a libby/rover pump so its a mechanical tdi..

you cannot put a idi pump on a tdi and work properly..

but you gotta fab intercooler, exhaust.. so unless you can fab things or can pay for fabbed parts.. it gets costly vs a standard turbo 1.6.. but as is your exceeding that.. so custom time..

does i thave ac? are you keeping the ac... what alt set up you plan to use? trust me those things important for under hood room.. why i asked above what do you have/run.. so i know room restraints

[Dean Erickson]

No AC  on the truck. The alt sets down low in front of the water pump so stock alt set up.  I am good at fab work I made my exhaust from front to back on my truck. I have a wire welder so I can do fab work. Libby/ rover pump? is that a pump that andrew makes for this set up?  What is the H.P. on a 1.9 td set up like this? I think I am looking at doing this when I put my truck up this next winter, so if I can get all my ducks in a row I will be all set.

[CRSMP5]

people i talked to say injectors, right turbo 200 before pump mods with a rover pump...

libby is a member here who sells/builds pumps.. his i think are cummins based vs rover based.. they all bosch just different brands use..

mine (rover w/gov mod)with real ic, exhaust, stock silly little turbo, finally cooked it, was more then enough to tow car from cali to ohio.. as i said.. i think its more stout then a 2.0 16v.. and running too much boost stock vr6 no issue.. mine pulls 6k rev like gasser too.. and its pulling.. not dead..

why did mine eat turbo.... somewhere i popped a coupler.. still made 15psi at manifold.. how much over spool? also hit a egt of 1450 for 5min thru mountain passes on west side of denver... those 2 things related, who knows.. had 305k miles on it and ive run it 18-21psi since my build.. those little kkk not supposed too... mine liked it..

yours is bigger so a power upgrade..  you just gotta find a tdi long block.. i suggest a 02a conversion.. a libby/rover pump and bolts in like yours is..

if you go with a serp alt set up.. the ic room becomes less..

what i would do in a non ac mk1 is side by side intercooler/rad.. make them thick and skinny.. just your alt set up will determine width of it all...