Who's built a powerhouse 1.6TD?

[libbydiesel]

Do you want a 'powerhouse 1.6 with forged rods, coated pistons and worked head' or do you want it simple? 

[wut_cel]

Do you want a 'powerhouse 1.6 with forged rods, coated pistons and worked head' or do you want it simple? 

I see what you are trying to say here but you're falling short of your point. Mechanical fuel pump and no boost controller, minimal gauges, and knowing it runs off one cable to the battery is simple. Is that not simple for you?

[bajacalal]

That's achievable with the TDI, just not with stock parts.

[wut_cel]

I'm looking to keep it simple (stupid) and a 1.6 idi is as basic as it gets. I love the simplicity of these motors and want to build one. If I wanted a fast car I wouldn't be driving a Volkswagen.

The DI engine is actually more simple, but not to split hairs .

Volkswagens can be super quick, and handle well. That is the really fun drive. Straight line cars, or 150mph+ cars aren't all too fun for daily or even common use.

I get 50mpg, and walk cars with double my horsepower. That is the fun part lol.

What exactly do you want the engine to do for you?

Quick is a good choice of words. I built a 200whp 16v NA'd mk1 that was quick. I've been in Porsche GT series race cars that are fast. I'm looking to build a motor that has a little more power and can handle a good beating, and not have to worry too much about it. I want the swap to be extremely simple, i.e. pulling a 1.6td out and putting one in in the same day. I don't need to go bigger, the stock 1.6td is fun for around town.

[8v-of-fury]

Alright, well if you want an in town machine.. a close ratio box with a tall 5th and the tiny k03 turbo is what you seek

I see max boost by 2200RPM and it is amazing in town. Snap the throttle while moving in 1, 2 or 3 and the tires will break free. 4th is not a tire breaker, but she squats ass and takes off.

The k14 would be your best bet if you do marginal to a lot of highway. The k03 can handle aggressive highway speeds, but it is not optimal.

[Gizmoman]

I know nothing about 1.6's but I have read a lot here over the last year. What's different between a 1.6 and a 1.9 IDI  (other than the obvious) - aren't they both just as "simple"?

[8v-of-fury]

Displacement, better head flow, bigger valves?, smaller and better turbo.

serp belt and bigger alternator.

[theman53]

better turbo is relative. I would hate it that small. Also it seems the 1.9 aaz has a weaker bottom end. For sure the rods aren't as strong and the main caps have seen some issues of late.

[8v-of-fury]

I think a lot of the bottom ends letting go were happening to people that were inside the engine. I don't really see how the next gen engine would have a weaker anything.. but it could happen I guess if they cheated us out.

[theman53]

I know smoking eddy was in a hurry and didn't open it at all. All of jimfoo's post show no mention of him opening the bottom. The only one I know was the tonytdtruck that completely rebuilt it.

They had a problem as they went from 65mm to 90mm main bolts. They wouldn't have done that if they were all ok, I don't think anyway.

[libbydiesel]

Do you want a 'powerhouse 1.6 with forged rods, coated pistons and worked head' or do you want it simple? 

I see what you are trying to say here but you're falling short of your point. Mechanical fuel pump and no boost controller, minimal gauges, and knowing it runs off one cable to the battery is simple. Is that not simple for you?

I didn't know I was making a point other than pointing out your inherent contradiction.  I have two TDIs that have mechanical pumps and will spank any 1.6TD you'll build, and both combined likely cost less than what you are proposing for your 1.6.  They will also get better fuel economy than a 1.6TD and will certainly last longer than a built 1.6.  Is that simple enough for you? Don't get me wrong, a 1.6TD is also a fine engine.  I have one in my rabbit and it moves it along just fine but if I was looking to maximize performance it would not be the right engine to start with. 

[libbydiesel]

For sure the rods aren't as strong and the main caps have seen some issues of late.

The AHU and AAZ mains are the same as the 1.6 but under a LOT more stress, especially in the AHU.  I don't think the longer bolts help.  They likely went to the longer bolts because they wanted to use weaker TTY bolts and needed more engagement to do so.  I think ARP mains are a good idea.  AHU rods are stronger than AAZ rods.

[wut_cel]

Do you want a 'powerhouse 1.6 with forged rods, coated pistons and worked head' or do you want it simple? 

I see what you are trying to say here but you're falling short of your point. Mechanical fuel pump and no boost controller, minimal gauges, and knowing it runs off one cable to the battery is simple. Is that not simple for you?

I didn't know I was making a point other than pointing out your inherent contradiction.  I have two TDIs that have mechanical pumps and will spank any 1.6TD you'll build, and both combined likely cost less than what you are proposing for your 1.6.  They will also get better fuel economy than a 1.6TD and will certainly last longer than a built 1.6.  Is that simple enough for you? Don't get me wrong, a 1.6TD is also a fine engine.  I have one in my rabbit and it moves it along just fine but if I was looking to maximize performance it would not be the right engine to start with. 

Funny, because the 1.9s are close to 3
$3000 down here.. How much did you think I was going to spend on my lil 1.6?

[8v-of-fury]

Funny, because the 1.9s are close to $3000 down here.. How much did you think I was going to spend on my lil 1.6?

More. To be as reliable and powerful as the 1.9 in even a mild tune.. it will take a lot to make up for the loss of displacement.

[Gizmoman]

I guess "Powerhouse 1.6 TD" is a bit subjective.
We have no clue as to your HP/Torque goals, but it's obvious you don't want to spend the bucks for a 1.9 (based on your location, I don't blame you) but here is the foundation you have to build from:

Code   Cyl   Valves   (L)   FI Type     Horsepower   Torque @ RPM  Comp     Bore      Stroke     CC      Turbo
1V   4   2   1.6L   Indirect Diesel      59 @ 4500   81 @ 2400                 23.0:1    76.5  86.4 1588     Yes   

A trip to Canada in a pickup could net this "foundation" for a lot less than getting one locally:
AAZ   4   2   1.9L   Indirect Diesel          75 @ 4200  107 @ 2400              22.5:1    79.5  86.5    1896     Yes

Over a 75% increase in HP and nearly the same increase in torque @ 300 RPM less

Increasing HP on either can get expensive but is relatively the same cost (unless you need a new head) - just a different outcome.