Author Topic: Rebuilding a 1.6 TD (Read 4825 times)

vwmike · « **on:** December 20, 2004, 10:17:58 pm »

I've rebuilt a few engines in the past, always with good results...but I've never rebuilt a diesel. A friend of mine has a 1.6 TD longblock that I was hoping to talk him out of. Problem is compression is low. I seem to recall him saying it pumped 170 psi. I don't know if that was in one cylinder or all of them....but that seems rediculously low. Anyways, here's my question: When rebuilding a VW diesel engine, or better yet a TD engine, is it common to have to replace the pistons and/or is there any issue with the cylinders going out of round? I'd love to just hone the block and put it back together with new bearings, rings, and bolts if I can.

jtanguay · « **Reply #1 on:** December 21, 2004, 03:04:12 am »

you could probably get away with new rings...

Rat407 · « **Reply #2 on:** December 21, 2004, 03:21:04 am »

I can say this much. My 91 Jetta TD had 162k on it and the oil was changed by the PO, (at least all the recepts in the glovebox showed 5k changes) and when I tore it apart the cylinders were out of spec out of round so I bored it .020 over. But reading on here most seem to get away with reringing. Personnally if you have the time and cash flow I would punch it out and do it right. Why try to just get by? But like I said it is a cash flow issue because the pistons are not cheap, at least not like a small block chevy.

vwmike · « **Reply #3 on:** December 21, 2004, 10:23:34 am »

Well, I can change the intermediate bearings... I actually have a set kicking around. But, if I don't have to replace the pistons, rebuilding the bottom end would probably only cost a few hundred dollars. Something tells me there's nothing wrong with the head.

chrissev · « **Reply #4 on:** December 21, 2004, 07:58:48 pm »

Quote from: "vwmike"

Well, I can change the intermediate bearings... I actually have a set kicking around. But, if I don't have to replace the pistons, rebuilding the bottom end would probably only cost a few hundred dollars. Something tells me there's nothing wrong with the head.

yeah the heads last a long time. Mine has 380.000 km on it and is still fine (except that some idiot overtorqued #1 and #2 cylinder injectors so now I have leaks). Your compression figure is very low. That engine is supposed to have over 400 psi per cylinder. What happens usually with the diesel is the cylinders, if really worn, become oval shaped. The only way to fix this problem is to bore them out and fit oversize pistons. Check if yours have this problem. If it is possible just to glaze bust them and then fit new rings then do it but with 170 psi compression I doubt it.

janb · « **Reply #5 on:** December 21, 2004, 08:17:22 pm »

Quote

Rebuild on a 1.6 TD will run between $800 - 1000 (US). The pistons in my rebuilt were $350 alone, although janb says that Halsey Auto sells them for a much better price.

Unfortunately Oversize Turbo D pistons are pretty spendy - like $350 !
NA's are pretty affordable, but I've not had to bore yet, plenty of spare blocks. I just grabbed 3 spare NA engines tonight, (project 'WVO genset') TD's are a bit more special :wink:

vwmike · « **Reply #6 on:** December 22, 2004, 12:26:27 pm »

Quote from: "janb"

Unfortunately Oversize Turbo D pistons are pretty spendy - like $350 !

That would be on the low end from what I've seen. It almost makes me think about JE's. Where did you see pistons for $350?