1.6 performance mods

[holoffs]

First time poster here. Actually pretty new to the whole diesel thing but my wife drives an 04 TDI, my son recently bought a 97 powerstroke and I recently aquired an 85 jetta 2 door diesel, non-turbo.  :? So here's my question(s). (1) If I wanted to get to say 90 hp. or so, can this be done with a stock turbo/injection pump setup? (2) Would I be better off to install a different turbo? If so, are there turbos from other cars that work well? (Audi 5000, Chrysler 2.2, etc. or are these too big??) I have several of these in my "inventory" which is why I ask. (3) Can the non-turbo injection pump be made to work with a turbo. If not, where can I get one for a reasonable price? (4) What is a 10mm or 12mm pump? (5) Does injection pump timing need to be changed when more air and fuel is introduced? I've fabricated numerous turbo setups for spark ignition vehicles so I am familiar with the principles of forced induction but not so much in the diesel realm. Any suggestions would be appreciated. (also, this is a budget project so I'm not interested in high dollar solutions)

[mk2vr6]

To be 100% honest, you'd be better off swapping a 1.6TD engine in and doing the few mods and tweaks to get to your 90HP.  The 1.6 n/a doesnt take too well to turbocharging or making big power, although by itseld it is still excellent on fuel and very reliable.

[BlackTieTD]

(also, this is a budget project so I'm not interested in high dollar solutions)

based on your situation and that last comment especially, i'd recommend going the route of a parts car with a good engine, or buying a complete swap engine and installing that. its probably the cheapest route but it depends if you get lucky on piecing it together...

[burn_your_money]

I have all the parts you need to get it to stock TD status but it would be cheaper for you to get your own complete TD engine and do an engine swap.

The NAs can be turboed no problem but once you start pushing high levels of boost and HP (IE 90) they tend to take a dramatic decrease in reliability and in their lifespan. For stock levels though most people would never notice a difference in reliability or lifespan

[holoffs]

Thanks for the info. Is the TD motor stronger internally than the non TD? The reason I ask is that I have access to a complete TD motor but is is pretty much worn out whereas my non-turbo 1.6 is fresh. What are the reliability issues you are suggesting?

[Audi80]

Oil squirters under pistons. These could be drilled to NA block. You also need to notch pistons for these.

[RabbitJockey]

i say it alot... but i don't think the oil squirters make that big of a difference...  if you keep ur egt's in check and everything is in good running order i don't see anything wrong with running a turbo on a n/a motor.  i think the importance of the oil squirters is drastically exaggerated.

[jtanguay]

well vw engineers put them there for a reason... if you want an extra 10-20 hp, then yea oil squirters aren't really necessary.  but if you wish to attain 140 hp or so... then yes oil squirters will be required.

the pistons are alloy and not porus... which means that they can swell up under intense heat quickly, resulting in scuffing and other intense damage in the cylinders.  

running an intercooler really helps keep the temps down as well...  but imo oil squirters are pretty good insurance for when those ricers come around

[foxracer1]

All the semi truck engines have them.

[burn_your_money]

If you think about it, VW out them there for a reason. They are on every VW TD sold, and even if they only cost $1/engine that is over a 1 million dollar cost to VW. They are there for a reason.
For stock levels I agree that they aren't as important but if you want 90 HP then I would say they are required. Use the TD head at the very least, it is stronger and the exhaust valves are different

[jtanguay]

those are the changes to the head to accomodate the turbocharging.

BUT... it seems as though VW sells the hydraulic heads with the same PN as non turbo heads... BUT were they actually manufactured all with turbo heads??? who knows...  might as well do it right

[RabbitJockey]

the head bolts were changed in 81 before the td was available (although i think you could get them in certain audis), and i thought the reason for the change was because the 11mm motors liked to go through headgaskets, just like the 1.5's which were also 11mm.

[mk2diesel]

the oil squirters a good for a 30 degree cooling effect on the bottom of the piston dome