building 1.6d to td tips?

[akcoalroller]

Hey guys, I have been browsing this forum for quite some time and finally got added today. just getting ideas for things i need to be able to get this build done up nicely. i got this car out of a field for free and have done a number of things to it now to get her looking alot better, still have more stuff for it that has yet to go on, just have to get back from work before i can start on it again. the original 1.6d stuck a valve and chewed up the head after i drove it a few thousand miles so i ended up finding a newer engine, still a 1.6d 11mm block, got a turbo pump for it, got a stock garrett T3/manifolds from a 1.6td and also ordered a tdi kit from hans with manifolds and turbo. have an audi a4 intercooler that we are going to shoehorn in for the turbo, plan to mod the pump a bit, throw in the 155bar injectors, got the proper oil pan pretapped for drain and have more parts on the way. any tips or suggestions for me? im just seeing what everyone would think. i assume i am heading in the right direction, oh also got the 8v head studs too, bought the 12mm on accident but luckily i have a buddy with a newer 1.6td that im going to get from him aswell. plan to keep this as a spare engine. also, i got a 5spd for $50 and was wondering if anyone has a link to where i can find the proper linkage to swap out from my 4spd to accommodate the 5spd. thanks a lot!

[745 turbogreasel]

If you are investing in parts, finding a lake to store the 11MM ones in comes to mind.

[akcoalroller]

haha thanks man. not really that helpful but its what i had at the time and the next one will be a hydraulic

[akcoalroller]

No thoughts at all?

Sent from my GT-I9300 using Tapatalk

[8v-of-fury!]

Been done and documented about 350,000 separate times .

Search my friend, the information is there. I've read it, and contributed to some.

[theman53]

The general consensus on the 11mm blocks is don't touch the head bolts unless you have to. They are known for cracking the block.
Search in the upgrades section first as I think that is where some have done the 4 to 5 speed swap. Look other places too, but I think someone did it in there not too long ago.

[bajacalal]

Just build the actual 1.6TD engine that you are in or will be in possession of. It's called "doing it right the first time" and slapping a turbo... a prothe turbo too, on a worn out 11mm engine really isn't anything close to that... Trust me, every time I take the cheap/easy option on these cars I wind up regretting it, they are kind of lightly built as it stands. Sure it will work but it won't last.

[Dakotakid]

^^^^THAT, AND, learn to "dismiss" the ding-dongs who occasionally come out of the woodwork and militantly "offer" their goofy hillbilly shortcuts (no...we ain't naming names....) on engine rebuilding and repair. You don't have to look far.....

[Mark(The Miser)UK]

My advise to you AK roller is to read, read and read all the relevant posts to your needs, and come to your own evaluated decision. 

[akcoalroller]

thanks guys. ill be going with what i have for now. its not going to be a daily driver at all. i had assumed that the 11mm block might not last for me. have nother one if needed :b ill have the 12mm at some point but its about 200 miles away so who knows when ill be making that trip.  that one i am hoping to do the frankenmotor build. it sounds like a fun project. this has become a spare time toy and i dont plan on making crazy horses out of it just want a little more pep in the step is all. as soon as i get the 1.6td ill have that on the stand and will be starting to get parts for it so it will be another fun engine to play around with. ill keep reading around and see what else i may need. i think i have just about everything in order so far. i just wanted opinions on whether i was going in the right direction for a lightly built engine that would be able to go up steep hills a little better.

[ORCoaster]

Mark, you point yourself out here as one to avoid?  Hmmm wouldn't have thought to do that. 

There are a whole host of us here that fit the "their goofy hillbilly shortcuts"  but we offer them just the same.  When it works for me all the time how am I supposed to know it isn't the proper way of doing it until someone like yourself points out the downside. 

You gotta get out of the "Why they always picking on me thoughts"  This is the internet!  Short of being a bunch of guys bashing each other all the time we occassionaly pass a good tip that makes things go click and varrrooommmm.

[theman53]

^^^^THAT, AND, learn to "dismiss" the ding-dongs who occasionally come out of the woodwork and militantly "offer" their goofy hillbilly shortcuts (no...we ain't naming names....) on engine rebuilding and repair. You don't have to look far.....

There are many, as I see you have names in plural...but some take offense so tread lightly on this. As much as I agree with you in that some ideas should be avoided, we are not really free unless we are free to make dumb decisions as well as good ones.

[akcoalroller]

also was curious about swapping to the sachs 210mm clutch kit, if i swap to this would it be best to upgrade the flywheel to 210mm aswell?

[8v-of-fury!]

^^ Cannot run a 210mm clutch disk inside a 200mm flywheel, for obvious size difference reasons. You can however run the smaller disks in the 210.. There is no added holding power over your 200mm stock setup by switching to a 210mm stock setup.

^^^^THAT, AND, learn to "dismiss" the ding-dongs who occasionally come out of the woodwork and militantly "offer" their goofy hillbilly shortcuts (no...we ain't naming names....) on engine rebuilding and repair. You don't have to look far.....

I know I am one of the people you are referencing.. Just because it is not in black and white in the Bentley manual does not mean it is a short-cut. There are quicker, easier and less expensive ways to do things than were written about 20 years ago.

[akcoalroller]

thanks, most the other threads i saw were about swapping to the 210mm 8v kit with the 210 flywheel creating more clamping force with the 210 clutch. i have never been a transmission guy and am trying to learn a little bit about the differences. before this it was all cummins and transmissions went to the shop. just after more knowledge. i see people are running what i am describing and claiming it makes a difference over stock. is this so?