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Engine Specific Info and Questions => IDI Engine => Topic started by: 81 vw pu on May 02, 2010, 01:10:20 am

Title: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on May 02, 2010, 01:10:20 am
First of all i'd like to say hello and thanks for all the information i've got from reading on this forum. This is a tdi setup that i purchased about 1-1/2 years ago before i came across this forum. ( and yes its from proth). Here are a few pics or my 81 vw pu 1.6 na to td build. I've been gathering parts for over a year to put a tdi turbo setup on a 1.6 na. i'm just mocking everything up now on a spare 1.6 and then i will transfer it to my pu.

(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0393.jpg)
(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0397.jpg)
(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0396.jpg)
(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0395.jpg)
(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0394.jpg)
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 8v-of-fury on May 02, 2010, 07:15:54 pm
That looks mighty fine what you got there, it will sure to be a real runner.

However there are some things you need to verse yourself on ;)

The VW 1.5, 1.6, and early (1993-1996 and some thereafter) 1.9 are IDI or Indirect Injection engines. The newer 1.9 (1996 Passats, 1997 and on Jettas, and 1998 and on Golfs) and later "Clean Diesels" are TDI or Direct Injection engines. Now just because there is a Turbo on an IDI engine does not make it a TDI. It makes it a Turbo Diesel IDI. These were offered throughout the Mk1 and Mk2 generations.

Nonetheless! It is a snazzy looking build!  :P Congrats
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on May 02, 2010, 08:57:02 pm
Thanks 8v, but i never stated i was building a tdi. I'm using the intake, exhaust, and turbo from a tdi on my 1.6 na to build a 1.6 td.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: truckoSaurus08 on May 02, 2010, 09:16:51 pm
At first I thought the same, but after reading some more I saw what you meant.
So whats the reasoning behind this set up? Will it clear the engine bay when you install it?
Also, in case you did not know,(you probably do) you should be careful on running a turbo on a N/a engine.
Oh yeah and I heard the intake ports on a TDi dont match the ports on an IdI.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: VW Smokr on May 02, 2010, 09:22:40 pm
Looks nice, 81 vw pu. Looking forward to hearing how it fits & performs in your truck.

Planning on installing an intercooler?

J.R.
SoCal
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 8v-of-fury on May 02, 2010, 09:32:06 pm
Thanks 8v, but i never stated i was building a tdi. I'm using the intake, exhaust, and turbo from a tdi on my 1.6 na to build a 1.6 td.

well don't I feel stoopid ;) my bad broski. Is the turbo a Prothe piece too?
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on May 02, 2010, 11:04:27 pm
The reason i went with this set up is from what i understand it only produces about 10 psi boost. That about what i'm looking for. I dont see any clearence issues yet, but i am going to have to extend that short downpipe and go over to the passenger side a little more. Yes the intake ports are different. The tdi intake has a D shaped port, and i'm trying to decide which gasket to use. Both gaskets cover the intake ports, but i like the na gasket better. I'm not installing a intercooler, just a hot pipe for now. I may turn fueling up a bit but not till my egt guage is installed. And yes 8v the intake, exaust manifold, turbo and downpipe are a kit i bought on e-bay from Proth.

 

Here are a few pics of the tdi intake and 1.6 na head ports.

tdi  D port intake
(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0400.jpg)
tdi intake with 1.6 na gasket
(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0401.jpg)
tdi gasket on 1.6 na head
(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0402.jpg)
another view of tdi gaskets on 1.6 na head
(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0399.jpg)
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on May 08, 2010, 12:42:13 am
Well I did the turbo install today and got to drive it tonight. I still have to fab a better downpipe
as the one that came with the kit is in the way of the relay shaft in 2nd and 4th gear.
here are a few pics of the progress.

Everything taken apart, ready to go back together.
(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0403.jpg)
Exhaust manifold and turbo bolted on.
(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0405.jpg)

TDI intake bolted on.
(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0406.jpg)

Drilled and tapped oil filter adapter for 1/8 pipe x -4an fitting.

(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0412.jpg)
Hot pipe from turbo to intake installed.
(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0407.jpg)
Oil return line installed.
(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0410.jpg)


Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on May 08, 2010, 01:29:16 am
Why didn't you use a 1.6TD manifold? 

These parts came in a kit I got from proth. I got the kit over a year ago, long before I
found this forum.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: truckoSaurus08 on May 08, 2010, 02:44:16 am
How much was the kit? Interested to see how it will turn out, especially it being a turbo from prothe, from witch i've heard a few bad things. Let us know how it runs and good luck with your project.
Nice caddy by the way.  8)
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on May 08, 2010, 03:08:25 am
Why didn't you use a 1.6TD manifold Interested to see how it will turn out, especially it being a turbo from prothe, from witch i've heard a few bad things. Let us know how it runs and good luck with your project.
Nice caddy by the way.  8)

The kit was $450.00, but I think they went up a bit. I got a cheaper price on one of his store sites than on his e-bay ad. I did my first burnout tonight with this caddy so I know its got more power.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: fatmobile on May 09, 2010, 12:32:20 am
The 1.6TD manifold is lame too.
 Good thing about this turbo is all that room above it.
You can use a cheap gasser intake that doesn't favor the center cylinders.

(http://img6.imageshack.us/img6/1695/vntrearview.jpg) (http://img6.imageshack.us/i/vntrearview.jpg/)




Title: Re: My 81 vw pu 1.6 na to td build
Post by: truckoSaurus08 on May 09, 2010, 06:42:32 pm
How about one of those pd 150 manifolds? I think thats what they are called.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: GEE-BEE on May 09, 2010, 08:45:29 pm
I have a 1Y intake that might will work....

With the intake tube and a air filter assy , better than that funky hose assy

GB

Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on May 09, 2010, 09:43:56 pm
Well I put about 60 miles on the TD caddy today. Its like driving a completely different pu. Its running about 2-3 lbs boost at 55 in 5th gear, about 5-7 with 3/4 throttle, and the most I saw was 11 lbs at wot. I noticed that the factory temp guage seem to run about 1 line cooler also. It really gets up to speed faster. Took it up a couple of hills and could gain speed instead of loosing now. Im very happy with the way it turned out, but like most of you, it will never be completely finished, theres always bigger and better parts. Thanks everyone and I'll keep you updated on any changes, (good or bad).
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on May 11, 2010, 12:44:34 am
Here a couple of pics of the new downpipe i had to build to clear the relay shaft. The downpipe that came with the kit was'nt even close. I also had to bend the top leg of the relay shaft down about an inch.

(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0414.jpg)

(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0413.jpg)
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on May 25, 2010, 02:40:02 pm
Well i have about 500 miles since i added the turbo, and I must say I have no regrets yet. Did the advance mod yesterday. I had to check 4 different pumps, to look for a green spring. The best i found was a red one so i used it with the 2 thinnest shims. Took her for a short drive and noticed quite an improvement in 1st and 2nd gear. The rpm's seem to climb higher and faster.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: ToddA1 on May 25, 2010, 10:46:05 pm
Well this boost my confidence in Prothe slightly.  Still not sure if I'd give him any of my money.  Glad it's up and running.

-Todd
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 8v-of-fury on May 25, 2010, 11:58:59 pm
its a good cheap kit. The rule of "you get what you pay for" applies. However, with anything cheap there is still a great success rate ;) Congrats!
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on July 02, 2010, 01:12:02 am
Well I have about 1500 miles since I added the turbo to the caddy, with only one minor problem. Had to tighten the fitting on the turbo for the oil supply line. I have tried several different valve cover breathers that vent crankcase vapors under the hood instead of running it back to the air intake, but sitting at a stoplight you can smell the vapors and I don't really care for that. Right now I have a hose from the block to a tee on the valve cover vent, and then down between the rack and pinion and firewall that's working good. No oil coming out on the ground or undercoating the truck. So far the prothe turbo kit has performed well for me and I would recommend it for anyone that can't find cheap stock td parts in their area as is the case around here. I have about $700.00 in the whole swap including all new studs and nuts. oil supply and return lines, air intake, hotpipe, and new straight-pipe exhaust. Also the stock 1.6na intake gasket hasn't failed (yet) on the D-port TDI intake, but I'm only seeing 10-11 lbs. boost max.  Thanks to everyone for all the great information on this site.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: punkvideo81 on July 02, 2010, 09:04:25 pm
Sounds like a cool build. Can you post some pics of your caddy? Or how about a video of a drive by? That would be sweet.   ;D
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on July 04, 2010, 03:23:09 pm
Sounds like a cool build. Can you post some pics of your caddy? Or how about a video of a drive by? That would be sweet.   ;D

 Here's a few pics of my 81 caddy punkvideo81.

(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0476.jpg)

(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0477.jpg)

(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0478.jpg)

Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on September 07, 2010, 03:34:13 pm
Just installed a dry nitrous kit on the caddy!!!  ;D  Anyone else running nitrous on their vw diesel???
Title: Re: My 81 vw pu 1.6 na to td build
Post by: punkvideo81 on October 05, 2010, 01:04:59 pm
this is getting even more interesting, how did it work?
Title: Re: My 81 vw pu 1.6 na to td build
Post by: Powered by Spearco on October 06, 2010, 01:24:29 am
Tell us more about the NOS. Which kit, how much, where did you hide the bottle, how did you route it and what not?  :).
Nice looking truck.
Whats up with the Jeep  ::).
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on October 06, 2010, 02:07:54 pm
this is getting even more interesting, how did it work?
I love it, spools the turbo faster and drops egt's by about 200 degrees.
I sprayed a 10 lb. bottle in less than a day doing some tuning with a 25 shot jet.
Tell us more about the NOS. Which kit, how much, where did you hide the bottle, how did you route it and what not?  :).
Nice looking truck.
Whats up with the Jeep  ::).
Its a dyno Tune universal efi kit 609.1 no bottle or brackets $179.00. The bottle is mounted in the bed on the ds front, but as soon as I can get a blowdown tube on the bottle its going back in the cab between the seats right below the back window. I ran the nos supply line down the ds along the brake lines and up by the master cylinder to the nos solenoid, and then over to the spray nozzle mounted in the intake. It has a arming switch that I put down by the emergency flasher button, and a micro switch I mounted on the injection pump so it only sprays at wot.
The jeep is a 1960 cj5 with a fuel injected 4.3, gm sm 420 4sp. dana 20. I built it about 10 years ago, but only gets driven 2-3 times a year now.

Title: Re: My 81 vw pu 1.6 na to td build
Post by: R.O.R-2.0 on October 07, 2010, 11:28:13 am
i had nitrous.. it was a waste of time in my eyes.. its over 50 bucks for a 10# bottle..

and i had a whole bottle sprayed out in no time. but the turbo makes more power, by far.. i never had them paired together tho. never had the want to do it. i had it hooked up on an n/a with a header, and it would make a difference, but not like being turbo'd or non turbo'd..
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on October 07, 2010, 12:58:22 pm
i had nitrous.. it was a waste of time in my eyes.. its over 50 bucks for a 10# bottle..

and i had a whole bottle sprayed out in no time. but the turbo makes more power, by far.. i never had them paired together tho. never had the want to do it. i had it hooked up on an n/a with a header, and it would make a difference, but not like being turbo'd or non turbo'd..

I buy the big bottles of nos from a welding shop and refill my own bottles, so its less tham $3 a lb. I was very disappointed the first time I sprayed the caddy, I didn't have enough fuel to take full advantage of the nitrous. After turning up the fuel and getting better results I bumped the nitrous from a 024 to 028 jet and added even more fuel. Its nothing like a monster shot on a gasser, but remember its a 4 cyl. diesel!!!
Title: Re: My 81 vw pu 1.6 na to td build
Post by: punkvideo81 on October 07, 2010, 03:57:21 pm
ok, time for a drive by video just as you hit the nitrous  ;D
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on June 05, 2011, 09:04:17 am
Here's a couple of crappy videos of my caddy at renegade raceway.

Time only run.
"http://www.facebook.com/v/232793063400923"

1st round red light!!!
"http://www.facebook.com/v/162250690455161"

Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on July 26, 2011, 03:27:51 pm
Update... Prothe turbo kit is still holding up with no problems. Its been well over a year and about 9,000 miles.
I did switch the TDI intake for a 1.6 TD intake a few months ago to see if I could tell any difference.
I think the TDI intake makes a little more power, so I may go back to that.
I just ordered a MBC so I can take boost up a little higher.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: R.O.R-2.0 on July 27, 2011, 03:05:34 pm
Update... Prothe turbo kit is still holding up with no problems. Its been well over a year and about 9,000 miles.
I did switch the TDI intake for a 1.6 TD intake a few months ago to see if I could tell any difference.
I think the TDI intake makes a little more power, so I may go back to that.
I just ordered a MBC so I can take boost up a little higher.

idk how a D port intake mani will make more power on oval ports..

doesnt even sound remotely possible..
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on July 27, 2011, 04:02:41 pm

idk how a D port intake mani will make more power on oval ports..

doesnt even sound remotely possible..
Don't know how it's possible myself man , but it did!!! The butt dyno don't lie. ;D
Title: Re: My 81 vw pu 1.6 na to td build
Post by: jseeley on July 27, 2011, 05:26:43 pm
Are you still using the NA pump? How well does that work... just run it rich till you hit boost?
Title: Re: My 81 vw pu 1.6 na to td build
Post by: dodger21 on July 27, 2011, 05:30:58 pm
Update... Prothe turbo kit is still holding up with no problems. Its been well over a year and about 9,000 miles.
I did switch the TDI intake for a 1.6 TD intake a few months ago to see if I could tell any difference.
I think the TDI intake makes a little more power, so I may go back to that.
I just ordered a MBC so I can take boost up a little higher.

idk how a D port intake mani will make more power on oval ports..

doesnt even sound remotely possible..

You can do what I did on a Cummins 12v head with a Commonrail 24v manifold. The 24v had round ports and the 12 head had square. Put the 12v gasket on the manifold and blend the port. Worked wonders for the conversion I was attempting.

OP, did you use the TDI gasket? I would blend ports if I was you to reduce turbulence and add a better flow path.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on July 27, 2011, 05:43:02 pm
Are you still using the NA pump? How well does that work... just run it rich till you hit boost?
Yes I'm still using the na pump, with gov mod (shimmed 2 washers), lighter advance spring, and fuel screw turned in about 1-1/2 turns right now.
Lots of smoke, even on 8 lbs boost, most of the time I set the fuel screw at 1/2 turn in to control smoke/EGT's.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on July 27, 2011, 05:55:22 pm
OP, did you use the TDI gasket? I would blend ports if I was you to reduce turbulence and add a better flow path.
On page 1 I have pics of the head, gaskets, and TDI manifold. I used the IDI round port gasket as it seemed to cover more area than the TDI gasket.
To blend/grind the head to use the TDI gasket would be best, but I never pulled the engine/head when I added the turbo parts.

Title: Re: My 81 vw pu 1.6 na to td build
Post by: R.O.R-2.0 on July 27, 2011, 07:07:09 pm
Are you still using the NA pump? How well does that work... just run it rich till you hit boost?
Yes I'm still using the na pump, with gov mod (shimmed 2 washers), lighter advance spring, and fuel screw turned in about 1-1/2 turns right now.
Lots of smoke, even on 8 lbs boost, most of the time I set the fuel screw at 1/2 turn in to control smoke/EGT's.

crank up your boost.. it works wonders.

im running ~16psi on my engine, and it only smokes till the turbo spools. the second the boost gauge is movin, the smoke is disappearing..

my pumps cranked up, gov mod'd, all that happy stuff (n/a pump)
Title: Re: My 81 vw pu 1.6 na to td build
Post by: nathan_b on July 27, 2011, 07:24:50 pm
Are you still using the NA pump? How well does that work... just run it rich till you hit boost?
Yes I'm still using the na pump, with gov mod (shimmed 2 washers), lighter advance spring, and fuel screw turned in about 1-1/2 turns right now.
Lots of smoke, even on 8 lbs boost, most of the time I set the fuel screw at 1/2 turn in to control smoke/EGT's.

crank up your boost.. it works wonders.

im running ~16psi on my engine, and it only smokes till the turbo spools. the second the boost gauge is movin, the smoke is disappearing..

my pumps cranked up, gov mod'd, all that happy stuff (n/a pump)

Yeah turn it up, was running 25psi on k24 , modded td pump ect.. was breaking tires free at 45mph in 3rd when boost came on : )

I want to go to the drag strip!!!
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on July 27, 2011, 09:47:45 pm
Just got my boost controller and installed while the last 2 people posted install a boost controller. I guess great minds think alike. LOL
First pass nothing over 8psi, lots of smoke egt buried at 1400F (gauge reads 100-1400F). Adjusted MBC 1 full turn in and saw 17psi, lighter smoke clearing as boost got higher, egt still1400F.
Third try backed off MBC 1/2 turn, fuel screw out 1/2 turn saw even lighter smoke, just a gray haze at 15psi but could still bury the egt gauge to 1400F just took a little longer.
More test-n-tune tomorrow, too many cops out right now. I think I'll turn down fuel a little more, but I like how fast it spools with lots of fuel.

PS no inter cooler yet but I do have a stock eclipse unit I could install.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: Powered by Spearco on July 28, 2011, 12:17:37 am
Cool dude. Isn't it fun playing with these engines and pumps.

Yes, get the intercooler piped in and you'll be impressed with the results.

Glad to see your conversion is still ticking along well. Keep us all posted with your results.

Title: Re: My 81 vw pu 1.6 na to td build
Post by: trav1856 on July 28, 2011, 12:30:15 am
First of all i'd like to say hello and thanks for all the information i've got from reading on this forum. This is a tdi setup that i purchased about 1-1/2 years ago before i came across this forum. ( and yes its from proth). Here are a few pics or my 81 vw pu 1.6 na to td build. I've been gathering parts for over a year to put a tdi turbo setup on a 1.6 na. i'm just mocking everything up now on a spare 1.6 and then i will transfer it to my pu.



I'm curious to know how it works for you.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on July 28, 2011, 01:00:21 am
First of all i'd like to say hello and thanks for all the information i've got from reading on this forum. This is a tdi setup that i purchased about 1-1/2 years ago before i came across this forum. ( and yes its from proth). Here are a few pics or my 81 vw pu 1.6 na to td build. I've been gathering parts for over a year to put a tdi turbo setup on a 1.6 na. i'm just mocking everything up now on a spare 1.6 and then i will transfer it to my pu.



I'm curious to know how it works for you.
So far its been a cool little conversion with no problems. 3 years ago I'd never even seen a IDI TD VW as they are pretty rare around here.
When I decided to turbo my na caddy. the prothe kit was as close to a complete kit as I could find. Since joining the forum I have been buying
up spare TD parts here and there. I now have almost 2 complete TD conversion kits plus the Prothe kit I'm currently running.



Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on July 28, 2011, 01:12:11 am
Cool dude. Isn't it fun playing with these engines and pumps.

Yes, get the intercooler piped in and you'll be impressed with the results.

Glad to see your conversion is still ticking along well. Keep us all posted with your results.
It is very fun and addictive Josh.

Any idea where to mount that little eclipse intercooler?? I've placed it all over the engine bay,
but have'nt found a place I like without running a fan on it. It would almost fit in the rain tray but don't know about air flow.
I would like to keep piping as short as possible.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: Powered by Spearco on July 28, 2011, 01:24:16 am
Sorry, I don't know what the Eclipse intercooler looks like. But if you need a Saab aluminium one that can fit infront of the rad, I'll let it go for cheap. Or you could cut a hole in the hood and add a NACCA duct for air flow with a fan too.

If your going to the car show I'll bring it for ya?
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on July 28, 2011, 01:45:15 am
Sorry, I don't know what the Eclipse intercooler looks like. But if you need a Saab aluminium one that can fit infront of the rad, I'll let it go for cheap. Or you could cut a hole in the hood and add a NACCA duct for air flow with a fan too.

If your going to the car show I'll bring it for ya?
They are small like maybe 10x10x4.

Really don't want to cut the hood, but would be willing to duct air from up front by radiator.
Have you had the saab intercooler in a mk1?  I may be interested in that.

I'm trying to find someone to go with me to portland sunday, but no takers yet.
If I come I'll be hauling the caddy on the rollback just in case it goes BOOM. ;D
Title: Re: My 81 vw pu 1.6 na to td build
Post by: Powered by Spearco on July 28, 2011, 01:56:38 am
I have not ran the Saab intercooler but I do know that it'll fit as I attemped to use one before the one I got now. Only slight modding to make it fit. Such as radiator mounting and plumbing to the intercooler.

Dude PM me your phone # before you go so we can meet up.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: trav1856 on July 28, 2011, 09:20:24 pm
First of all i'd like to say hello and thanks for all the information i've got from reading on this forum. This is a tdi setup that i purchased about 1-1/2 years ago before i came across this forum. ( and yes its from proth). Here are a few pics or my 81 vw pu 1.6 na to td build. I've been gathering parts for over a year to put a tdi turbo setup on a 1.6 na. i'm just mocking everything up now on a spare 1.6 and then i will transfer it to my pu.



I'm curious to know how it works for you.


...and everyone else said I was crazy for wanting to do this. But I thank you for sharing your results. That gives me a little more faith.
So far its been a cool little conversion with no problems. 3 years ago I'd never even seen a IDI TD VW as they are pretty rare around here.
When I decided to turbo my na caddy. the prothe kit was as close to a complete kit as I could find. Since joining the forum I have been buying
up spare TD parts here and there. I now have almost 2 complete TD conversion kits plus the Prothe kit I'm currently running.




Title: Re: My 81 vw pu 1.6 na to td build
Post by: trav1856 on July 28, 2011, 09:21:43 pm
Cool dude. Isn't it fun playing with these engines and pumps.

Yes, get the intercooler piped in and you'll be impressed with the results.

Glad to see your conversion is still ticking along well. Keep us all posted with your results.
It is very fun and addictive Josh.

Any idea where to mount that little eclipse intercooler?? I've placed it all over the engine bay,
but have'nt found a place I like without running a fan on it. It would almost fit in the rain tray but don't know about air flow.
I would like to keep piping as short as possible.

I saw one that fit in a box and they cut an intake thru the hood...kind of like a hoodscoop, but off-set, it was interesting looking.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on July 30, 2011, 01:57:42 am
Made some major progress yesterday with smoke/high EGT's While on boost. I've adjusted that fuel screw, idle screw and MBC With every different combination I could think of.
Fuel screw out= no boost
Fuel screw in = Good boost but high EGT's and lots of smoke no matter where I set MBC.
What gives, when on nitrous smoke clears and Egt's are fine.And then it hit me,( I don't Have enough air going into this S.O.B).
Took off the Mickey mouse air intake I had on and spent a few hours building a new one. Used the same cone air filter and 3" pipe to 2-1/2 and then down to 1-3/4 turbo inlet.
Went for a drive and barely any smoke on 15psi boost and 200F cooler on EGT's. Been starving this poor ole 1.6 for air for over a year now!!!
Title: Re: My 81 vw pu 1.6 na to td build
Post by: DieselBalz on July 30, 2011, 03:07:18 am
Cool dude. Isn't it fun playing with these engines and pumps.

Yes, get the intercooler piped in and you'll be impressed with the results.

Glad to see your conversion is still ticking along well. Keep us all posted with your results.
It is very fun and addictive Josh.

Any idea where to mount that little eclipse intercooler?? I've placed it all over the engine bay,
but have'nt found a place I like without running a fan on it. It would almost fit in the rain tray but don't know about air flow.
I would like to keep piping as short as possible.

I saw one that fit in a box and they cut an intake thru the hood...kind of like a hoodscoop, but off-set, it was interesting looking.

There is a build thread here http://www.vwdiesel.net/forum/index.php?topic=11060.0 that shows a top mount with a Saab intercooler. This is exactly what I plan on doing. I like the idea of a fan I can switch on if I get stuck in traffic. I am not going with the hood scoops though. I am thinking just one louver with the slits facing backwards over the intercooler so it will scoop the air down at speed.

(http://i154.photobucket.com/albums/s256/sale12345/Turbobunnybuild04044.jpg)

(http://i154.photobucket.com/albums/s256/sale12345/NewMexicoTrip1002.jpg)

The scoops are just too much for me. I am thinking of something like this.. http://www.hrpworld.com/index.cfm?form_prod_id=3876&action=product
I already have the intercooler, just need to relocate the battery and delete the washer reservoir.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: trav1856 on July 30, 2011, 05:58:43 pm
They were close to the picture you listed, but more back towards the coolant/windshield washer tank, and it didn't have the cowling, it was just essentially a square hole in the hood.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: RabbitJockey on July 30, 2011, 06:25:49 pm
i think louvers would look cool, from what i have read, most hood scoops do next to nothing for scooping in air, i'd put a nice heavy fan on that intercooler and seal it around the opening of the hood that way u no its sucking outside air through it.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: RabbitJockey on July 30, 2011, 06:28:33 pm
i really like this cars intercooler setup as well, its kinda weird how much u don't notice it,  and it supports 430whp haha.  imagine racing somebody in a corvette or any fast car with a cabriolet that has 430whp.  haha  he told me it his speedo goes to 160mph, and he can pin it.  met the guy at a car show

forgot to post the link haha

http://www.youtube.com/watch?v=cZ1dBZQMHbo
Title: Re: My 81 vw pu 1.6 na to td build
Post by: DieselBalz on July 30, 2011, 10:34:42 pm
i think louvers would look cool, from what i have read, most hood scoops do next to nothing for scooping in air, i'd put a nice heavy fan on that intercooler and seal it around the opening of the hood that way u no its sucking outside air through it.

Right, I was planning on using some simple foam sheets around the ICso when the hood closes down it makes a quasi seal.

I was thinking about the fan though, would I just use a small sized radiator fan? Its 12v and water proof/resistant? Am I missing anything else I should be thinking about?

Also to the OP, love this build. Its the kinda stuff that inspires those of us gettin started on our toys.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: trav1856 on August 01, 2011, 12:32:36 am
i really like this cars intercooler setup as well, its kinda weird how much u don't notice it,  and it supports 430whp haha.  imagine racing somebody in a corvette or any fast car with a cabriolet that has 430whp.  haha  he told me it his speedo goes to 160mph, and he can pin it.  met the guy at a car show

forgot to post the link haha

http://www.youtube.com/watch?v=cZ1dBZQMHbo

THAT is the one I was talking about.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on September 15, 2011, 01:35:27 am
Got a intercooler off e-bay a couple weeks ago and just installed it last friday. Dropped egt's about 200 degrees cruising on flat road.
Had to move the radiator over and reroute oil cooler lines. Got less than $200 in intercooler, piping. couplers and clamps.
Here's a few pics.

(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0779.jpg)

(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0777.jpg)

(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0778.jpg)



Title: Re: My 81 vw pu 1.6 na to td build
Post by: keaton on September 15, 2011, 03:36:47 am
Got a intercooler off e-bay a couple weeks ago and just installed it last friday. Dropped egt's about 200 degrees cruising on flat road.
Had to move the radiator over and reroute oil cooler lines. Got less than $200 in intercooler, piping. couplers and clamps.
Here's a few pics.

(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0779.jpg)

(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0777.jpg)

(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0778.jpg)



might wanna put some ducting around the IC to the front of the car. air will take the path of least resistance and its easier to go around the IC vs through it....
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on September 15, 2011, 04:16:07 am


might wanna put some ducting around the IC to the front of the car. air will take the path of least resistance and its easier to go around the IC vs through it....

I'm sure some type of funnel shaped ducting would help channel more air through the intercooler, but I don't know if it would be worth the extra work to do so.
I might cover the gap on top and call it good. As it is now the pipe from intercooler to intake is cool right after shutdown.

Here's a view from the grill.

(http://i814.photobucket.com/albums/zz63/dawgsrepo/IMG_0780.jpg)
Title: Re: My 81 vw pu 1.6 na to td build
Post by: Powered by Spearco on September 15, 2011, 10:39:38 am
 :o :o. Dude that looks nice. Great location and install on that intercooler. Thats the one that I was going to give to you. Looks great.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: DieselBalz on September 15, 2011, 02:59:23 pm
Looks great. Where did ya get the piping and couplers from?
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on September 15, 2011, 03:23:26 pm
:o :o. Dude that looks nice. Great location and install on that intercooler. Thats the one that I was going to give to you. Looks great.
Thanks Josh, I wish I could have got the one from you, I got this one for $37.50 delivered off e-bay.

Looks great. Where did ya get the piping and couplers from?

Thanks DieselBalz.
Couplers and clamps I got Here. 
http://www.siliconeintakes.com/

Pipe is just 2" exhaust bent at local muffler shop. Pipe+bends cost $16.23.
Title: Re: My 81 vw pu 1.6 na to td build
Post by: vanbcguy on September 15, 2011, 10:14:07 pm
Very nice!!
Title: Re: My 81 vw pu 1.6 na to td build
Post by: 81 vw pu on February 13, 2012, 01:11:11 am
Another update on my never ending build. About 2 months ago I got bored and decided to take off the prothe GT15 clone and install a vw K24 I had purchased from a member here.
Leaving the pump and MBC setting as they were with the GT15, I could rev to 2500-3000 in neutral and not make any boost (just a little turbo whine). Took her for a test drive and got a big surprise.
The K24 starts making boost at the top of 1st gear and by the top of third it hit 25 psi so back to the shop to turn fuel and MBC down. I now have fuel screw in about 1.5 turns in from hanging throttle
and boost controller set 1 turn in from spring/ball being loose. It will still make 20 psi by the top of 3rd but now I have to really stay in the throttle to get egt's over 1200F. Overall I like the K24
over the smaller GT15. Cruising at 55= 2-3 psi and not near as much lag as I expected. Also went from 2" straightpipe to 2.5 downpipe only ;D
Title: Re: My 81 vw pu 1.6 na to td build
Post by: R.O.R-2.0 on February 13, 2012, 12:20:26 pm
Another update on my never ending build. About 2 months ago I got bored and decided to take off the prothe GT15 clone and install a vw K24 I had purchased from a member here.
Leaving the pump and MBC setting as they were with the GT15, I could rev to 2500-3000 in neutral and not make any boost (just a little turbo whine). Took her for a test drive and got a big surprise.
The K24 starts making boost at the top of 1st gear and by the top of third it hit 25 psi so back to the shop to turn fuel and MBC down. I now have fuel screw in about 1.5 turns in from hanging throttle
and boost controller set 1 turn in from spring/ball being loose. It will still make 20 psi by the top of 3rd but now I have to really stay in the throttle to get egt's over 1200F. Overall I like the K24
over the smaller GT15. Cruising at 55= 2-3 psi and not near as much lag as I expected. Also went from 2" straightpipe to 2.5 downpipe only ;D

really? you like the K24? i just swapped to one also.. same thing, it makes no sound at idle, but bring it up to 3 grand and it starts screamin..

i havent had a chance to drive mine yet tho, so i dunno how its going to react as well as boosting up.. i know im going to miss my "full boost in every gear" turbo...

and i have plenty of fuel, i imagine im going to be able to hit 25-30 psi pretty easily..