Author Topic: 96-98 TDI block = 1.6 block?? (Read 5841 times)

klr650@ · « **on:** October 17, 2006, 05:35:04 am »

Not sure if this in the right section.......

Does anyone know if the 96-98 TDI block is the same as the older 1.6 block it replaced? I've heard it is and all the 1.6TD accessories with fit (except the pump, I'd go with a mechanical one). I'd like to upgrade to the TDI. Anyone know for sure?

Thanks,
Dave

QuickTD · « **Reply #1 on:** October 17, 2006, 05:41:02 am »

The AHU has the same engine mount locations and the same accessory mount holes. The block is a bit taller (20mm?) so your downpipe may have to be modified. The TDI has "D" shaped ports in the intake manifold, so an oval port 1.6 intake will not seal against the TDI head, so you'll need to use a TDI intake or one from an AAZ (1.9TD).

klr650@ · « **Reply #2 on:** October 17, 2006, 06:22:51 am »

So the extra 20mm in height... would the extra clearance be needed on the top (hood) or the bottom. I guessing since the engine mounts are the same the extra clearance would be needed on top.

QuickTD · « **Reply #3 on:** October 17, 2006, 06:25:02 am »

The clearance is required at the top. The mount holes are the same in relation to the oil pan and crank.

klr650@ · « **Reply #4 on:** October 17, 2006, 06:39:35 am »

very cool. The zuki I plan on putting one in has the clearance on top but not the bottom.

Does the AHU/1Z style have the electronic shutoff thingy? I actually think its called an anti-theft device, where the engine, ecm and key/ignition all need to talk in order for the engine to run. Obvisiously I won't have all that.

vwmike · « **Reply #5 on:** October 17, 2006, 09:50:36 am »

The immobilizer systems weren't used with those engines. That was in the MK4's where they started doing that.

macsdub · « **Reply #6 on:** October 17, 2006, 03:57:33 pm »

i got an ahu tdi-M in a rabbit
i think its a great upgrade to replace a tired 1.6td if you have a tdi engine avalable
and yes all accys bolt right up
i used all my std 79 rabbit accys
i had someone build me a 12mm pump,and theres some controversy stil lto as if a 9mm(stock) pump would run a tdi
they say you need the bigger plunger(10-11mm) in order to get the injectors to flow fuel
im thinkin itll run,it just may not be a rocketship,but itll be way faster than a 1.6td
heres a few pics of mine

i was runnin mid 14's at waterfest
ive run a best of 14.07

Slave2School · « **Reply #7 on:** October 17, 2006, 04:13:19 pm »

I like th ered-top there

I have teh Canadian tire cheap version (not the same reserve blah blah...wait that's tdi club talking agian...) Why did you go to it? For the sealed aspect or the fact that it handles vibrations better?

macsdub · « **Reply #8 on:** October 17, 2006, 08:41:41 pm »

um,im a little confused
red top???maybe you mean my plug in my breather on the v/c
i couldnt get a standard tdi block to breather hose to fit because of the reuse of the idi turbo oil feed line,and this pic was before i fabbed up a crankcase vent with other style of hose....
over 10-maybe 12k miles on it now,and it runs like a charm,every day
id like better heat for the winter though,,im gonan try upgrading to a 90 amp alternator+then adding those coolant glow plug heaters back in the water outlet on the head

scopefrfd · « **Reply #9 on:** October 20, 2006, 05:53:47 pm »

I have a euro factory bosch pump that has the 10mm pump head and the smaller pump shaft. I would assume if bosch designed it right from the factory with a 10mm head and smaller input shaft..then I would think putting a 10mm pump head on a older 9mm pump is ok.

I would never put an 11mm head on a small shaft pump...the 11mm springs are much much stiffer than the 10mm springs and I would think the shaft would break over a period of time.

Slave2School · « **Reply #10 on:** October 20, 2006, 06:09:04 pm »

Red Top optima battery

macsdub · « **Reply #11 on:** October 21, 2006, 12:24:09 pm »

oh ok,,optima
yea i like them alot,better than nasty acid filled ones
yea its a small shaft pump,it has a 12mm head on it
its a "time bomb",look out dont use one of those :roll:
i been waitin for it to blow now for 3 or 4? years now... i used to have this same built pump on my 1.6td before i put it on the tdi
just cause 1 guy busts a pump that was setup like that(12mm head/small shaft),everyone is scared to do it
ask giles,even a stocker can break like that over something like incorrect torque of the head to housing bolts,the plunger can sieze+whammo,itll break the shaft.......