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Author Topic: VW 1.6 NA to Turbo swap! Questions and Progress.  (Read 23163 times)

Reply #60May 17, 2017, 12:15:46 am

Dakotakid

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Re: VW 1.6 NA to Turbo swap! Questions and Progress.
« Reply #60 on: May 17, 2017, 12:15:46 am »
According to Bentley:
Using NEW valve stems: 1.3 mm for exhaust..........1.0 mm for intakes
The exhaust stems are slightly smaller than the intakes.....even though they are both referred to as 8 mm stems. Obviously, the exhausts grow slightly larger with heat.

I use a 0.315 inch reamer for the exhaust followed with slight cleaning hone. I used a 0.3155 inch reamer for intakes followed with slight hone for smoothing. My job turns out slightly larger than the Bentley specs. I lose a little guide wear....but, I KNOW they will not stick in the new engine.

In the future, I will use the 0.315 in both holes and use more lubrication to get slightly tighter clearances.

There are also manufacturer differences in the stems (although (of course) not much). TRW's are slightly larger......Sealed Power and Osvats are a red-one smaller than the TRW's.

Of course, wobbling valves is not "accurate" as the guides wear oblong due to the rotational effect of the cam. But....what the hey............

I GUARANTEE you need at LEAST exhaust guides in virtually any used head.
The mask and the shot(s) are actually an IQ test. If you are wearing or circulating, you just failed the test. I can't feel sorry for you.

Reply #61May 23, 2017, 12:17:57 am

Tmarkle

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Re: VW 1.6 NA to Turbo swap! Questions and Progress.
« Reply #61 on: May 23, 2017, 12:17:57 am »
Haven't gotten any farther with the car. I've become leery of taking the head to a machinist after reading horror stories of dropped precups. If I could afford a new head I would do that but that's not an option right now either.


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1985 Jetta 1.6 NA, Project
1981 Rabbit 1.5 diesel SOLD
1980 Dasher, also a project
1993 Passat GLX VR6 (daily driver)
1992 Toyota Pickup, 350 V8 swapped
1997 Jetta TDI, engine donor for a diesel powered Toyota!
1986 Toyota Custom Cab

Reply #62May 24, 2017, 12:26:38 am

Tmarkle

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Re: VW 1.6 NA to Turbo swap! Questions and Progress.
« Reply #62 on: May 24, 2017, 12:26:38 am »
Well I finally got the time and motivation to crack open the motor. Four valves appear to have hit pistons. On the bright side cylinders have virtually no lip (can't catch my nail) no prechamber cracks, and the head surface looked pretty good after some clean up. Is there a way to tell if the valves are bent or should it not even be investigated and just replace them?


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1985 Jetta 1.6 NA, Project
1981 Rabbit 1.5 diesel SOLD
1980 Dasher, also a project
1993 Passat GLX VR6 (daily driver)
1992 Toyota Pickup, 350 V8 swapped
1997 Jetta TDI, engine donor for a diesel powered Toyota!
1986 Toyota Custom Cab

Reply #63May 24, 2017, 12:28:45 am

Tmarkle

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Re: VW 1.6 NA to Turbo swap! Questions and Progress.
« Reply #63 on: May 24, 2017, 12:28:45 am »



Sent from my iPhone using Tapatalk
1985 Jetta 1.6 NA, Project
1981 Rabbit 1.5 diesel SOLD
1980 Dasher, also a project
1993 Passat GLX VR6 (daily driver)
1992 Toyota Pickup, 350 V8 swapped
1997 Jetta TDI, engine donor for a diesel powered Toyota!
1986 Toyota Custom Cab

Reply #64May 24, 2017, 12:29:29 am

Tmarkle

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Re: VW 1.6 NA to Turbo swap! Questions and Progress.
« Reply #64 on: May 24, 2017, 12:29:29 am »
Also what's the best way to clean any debris out of the cylinders? Brake clean and air?


Sent from my iPhone using Tapatalk
1985 Jetta 1.6 NA, Project
1981 Rabbit 1.5 diesel SOLD
1980 Dasher, also a project
1993 Passat GLX VR6 (daily driver)
1992 Toyota Pickup, 350 V8 swapped
1997 Jetta TDI, engine donor for a diesel powered Toyota!
1986 Toyota Custom Cab

Reply #65May 24, 2017, 01:37:51 am

vanbcguy

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Re: VW 1.6 NA to Turbo swap! Questions and Progress.
« Reply #65 on: May 24, 2017, 01:37:51 am »
Valves tend to compress when hit - the stem gets fatigued but the valve stays "straight". The stem will be shortened slightly... There may be some noticeable wobble rolling the stem on a table but it often isn't all that obvious. This is the cause of a lot of trashed engines - people try to get away with just a new belt. The valve still seals so it "seems" like everything is good to go. Then a couple thousand miles later the head drops off the valve and completely DESTROYS the piston, head and possibly the block. If you're really lucky you bend a rod too.

New valves are cheap compared to the rest of the engine - once you have the valves pulled for inspection I'd be tempted to replace any that hit pistons.

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Bryn

1994 Jetta - AHU M-TDI - Jezebel Jetta
2004 Jetta Wagon - 1.8T - Blitzen

Reply #66May 24, 2017, 01:52:12 am

libbydiesel

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Re: VW 1.6 NA to Turbo swap! Questions and Progress.
« Reply #66 on: May 24, 2017, 01:52:12 am »
New valves are cheap compared to the rest of the engine - once you have the valves pulled for inspection I'd be tempted to replace any that hit pistons.

Your post is right on except I think you're understating it a bit.  If there is any indication at all that a valve and a piston made contact I wouldn't just be tempted, I'd most certainly replace it. 

Reply #67May 24, 2017, 03:39:57 am

Dakotakid

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Re: VW 1.6 NA to Turbo swap! Questions and Progress.
« Reply #67 on: May 24, 2017, 03:39:57 am »
If the valves are suspected units due to contact.....the lifters must be considered as well.

This is the first time I have ever seen true "first-over" pistons. I would go ahead and compare piston protrusion among the four. But, I would NOT pull those pistons unless you HAVE to because finding rings for those will be difficult......unless Hastings or some other off-beat. This is why you do not have much of a ridge.
« Last Edit: May 24, 2017, 03:45:27 am by Dakotakid »
The mask and the shot(s) are actually an IQ test. If you are wearing or circulating, you just failed the test. I can't feel sorry for you.

Reply #68May 24, 2017, 07:47:18 am

RabbitJockey

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Re: VW 1.6 NA to Turbo swap! Questions and Progress.
« Reply #68 on: May 24, 2017, 07:47:18 am »
pull the lifters and flip them over, you can tell if there is damage

01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #69May 24, 2017, 08:25:59 am

Tmarkle

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Re: VW 1.6 NA to Turbo swap! Questions and Progress.
« Reply #69 on: May 24, 2017, 08:25:59 am »
If the valves are suspected units due to contact.....the lifters must be considered as well.

This is the first time I have ever seen true "first-over" pistons. I would go ahead and compare piston protrusion among the four. But, I would NOT pull those pistons unless you HAVE to because finding rings for those will be difficult......unless Hastings or some other off-beat. This is why you do not have much of a ridge.
What would be a situation were I'd have to replace the pistons? I don't know if I mentioned that every single piston has a valve mark. Most of the marks are pretty much just visible but one has a ridge half way around I can catch my nail on easily (one pictured).


Sent from my iPhone using Tapatalk
1985 Jetta 1.6 NA, Project
1981 Rabbit 1.5 diesel SOLD
1980 Dasher, also a project
1993 Passat GLX VR6 (daily driver)
1992 Toyota Pickup, 350 V8 swapped
1997 Jetta TDI, engine donor for a diesel powered Toyota!
1986 Toyota Custom Cab

Reply #70May 24, 2017, 08:27:36 am

Tmarkle

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Re: VW 1.6 NA to Turbo swap! Questions and Progress.
« Reply #70 on: May 24, 2017, 08:27:36 am »
And what's a "first over" piston?


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1985 Jetta 1.6 NA, Project
1981 Rabbit 1.5 diesel SOLD
1980 Dasher, also a project
1993 Passat GLX VR6 (daily driver)
1992 Toyota Pickup, 350 V8 swapped
1997 Jetta TDI, engine donor for a diesel powered Toyota!
1986 Toyota Custom Cab

Reply #71May 24, 2017, 08:49:57 am

RabbitJockey

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Re: VW 1.6 NA to Turbo swap! Questions and Progress.
« Reply #71 on: May 24, 2017, 08:49:57 am »
pistons would depend on personal preference, they dont sound too bad, just make sure the rods aren't bent.  I would only replaced them based on whether or not the engine needs overbored, which is decided by cylinder bore wear and compression numbers.

First over piston would be the first size over stock piston, so a 77mm piston because 0.50mm over size is the "first over" size piston.
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #72May 24, 2017, 08:54:57 am

Tmarkle

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Re: VW 1.6 NA to Turbo swap! Questions and Progress.
« Reply #72 on: May 24, 2017, 08:54:57 am »
pistons would depend on personal preference, they dont sound too bad, just make sure the rods aren't bent.  I would only replaced them based on whether or not the engine needs overbored, which is decided by cylinder bore wear and compression numbers.

First over piston would be the first size over stock piston, so a 77mm piston because 0.50mm over size is the "first over" size piston.
Cylinders look good so I think that's ok. @dakotakid is saying that my engine has oversized pistons? Like it's been rebuilt once or was I misunderstanding his statement?


Sent from my iPhone using Tapatalk
1985 Jetta 1.6 NA, Project
1981 Rabbit 1.5 diesel SOLD
1980 Dasher, also a project
1993 Passat GLX VR6 (daily driver)
1992 Toyota Pickup, 350 V8 swapped
1997 Jetta TDI, engine donor for a diesel powered Toyota!
1986 Toyota Custom Cab

Reply #73May 24, 2017, 12:03:11 pm

RabbitJockey

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Re: VW 1.6 NA to Turbo swap! Questions and Progress.
« Reply #73 on: May 24, 2017, 12:03:11 pm »
looking and being are 2 different things haha

you can buy the two tools you need for measuring bores for less than 100 dollars if you're interested in being scientific about it

How ever in my opinion, if it had good cold starts before, didn't have a bunch of piston slap, didn't burn a bunch of oil, and the bores don't have any obvious problems then i wouldn't worry about it.
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #74May 24, 2017, 02:20:26 pm

Dakotakid

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Re: VW 1.6 NA to Turbo swap! Questions and Progress.
« Reply #74 on: May 24, 2017, 02:20:26 pm »
Markle: yes, that is exactly what I am saying. Look at the stamp on the top of the piston: "25/D" Indicates first over which is very infrequent and difficult to source those pistons and rings. However, this immediate middle section in the discussion makes me glad this forum still has the ignore feature. Headed there now................
The mask and the shot(s) are actually an IQ test. If you are wearing or circulating, you just failed the test. I can't feel sorry for you.

 

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