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Engine Specific Info and Questions => IDI Engine => Topic started by: Hiho on April 19, 2009, 03:28:04 am
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Hello all.
I'm new to the forum but have had diesel golfs for a couple of years now. I have just bought a great new 1978 GLD that is going to be turbocharged.
Its 1.5 NA
Now before you all advise me not to, I must say that unfortunately i have little choice as the 1.6TD was never released here. And from reading posts on this forum, it appears that there are some benefits from using the 1.5 in terms of top end (for a diesel anyway).
What I would like to know is what I have to do to the internals to make it reliable and turbo tolerant? Will longer head bolts do or will i need to go to longer and larger 12mm bolts? Do i really need oil squirters? Does any of this make a difference?
Also, what parts do i need to bolt onto the outside? Whats the best injector pump? Can i add the LDA from a 1.6TD pump to the 1.5NA pump? Can i simply use a 1.6TD pump?
What turbo should I use? I intend to intercool and have a decent exhaust
At this point i should state my intention for the car. I would like driveability, reliability and economy, and a useable overdrive (.76). I am not a drag racer, but I do like to drive spritely on a windy road in the hills.
Should i buy a kit like those sold on ebay? Does anyone have any experience with these kits (sold by prothe)?
Any experiences or advice is welcome.
Thanks
Matt
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Where are you from?
you can use all theese parts from a 1.6 gtd, injection pump, injectors, intake manifold, oil pan, oil lines (both feed and return), oil filter housing (maybe), exhuast manifold, turbo (k14 is your best bet, k24 for more top end boost)
oil squiters will make a difference in longevity, but if your keeping boost low (15psi??, someone can chime in on that)), and possibly add a oil cooler you can get away without them.
but if your 1.5 is worn out and you are planning a rebuild, i would add them.
you can do some tweaks to your injection pump get some performance, but a rebuilt pump fully modified will give you the best performance.
the FAQ has lots of info on these subjects.
hth
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ok, so, i have a 1.5 TD.. and im definitely not gonna tell you it wont work. i favor the 1.5's. if you arent going to throw tons of boost or fuel at it, just go with a stock gasket and head studs. might even get away with stock bolts, but studs are better. i dont have an oil cooler or oil squirters, but i do have a turbo oil pump. ive got a n/a fuel pump on mine ATM, and it gives the engine OK fueling. i really havent messed with this pump yet. and honestly.. if this engine can stand up to my right foot.. i dunno why anyone would be able to kill it. you can turn these engines so many rpm's that they actually start making LESS noise.
what kinda turbo you planning on putting on there? ive got a VNT 17 and it works quite well. im also running a gas intake manifold off a 92 jetta. it has long, tapered runners and a nice big plenum, less chance for pressure bias to # 2 and 3 cylinders. im running 2.5 inch all the way from the turbo to the flowmaster. you probably wont want to run a muffler, since most people on here prefer the str8 pipe.
theres plenty of other people on here with turbo 1.5D's. sauerkraut is another one running a 1.5TD. i dunno the extent of his build, but i know mine is really fun to drive.
if you got anymore questions, get at me, or sauerkraut, or any of us really.
As for the prothe turbo kit.. myself personally, i wouldnt buy it. its all cheap chinese made parts. and it comes with a 1.9 intake manifold. they have D shaped ports.. 1.5 and 1.6 have oval oblong ports. so obviously there is going to be turbulence in the intake. but if thats the only route you can go, then you can be a test guinea pig... :twisted:
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I will not try and stop you, but I will suggest pictures and progress reports when it happens. That's my final offer.
1SlowVW
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why to stop you?
i have a 1.6mech n/a converted to turbo and i have made more than 100.000km running 2 bar(now 1.5 as the k24 is giving up).
changed to metal hg,external oil cooler and big i.c. in front.
still running as strong as the day i did the first ride 8)
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i agree the prothe kit is poo, its like a bunch of miss matched left over parts.
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Hello again,
Im in Australia, land of the long tooth Golf. Heres my new project. It came with GTI grill and completely stuffed electrics. I suspect that the previous owner roll started it with no oil in the sump (leaking drain plug) so maybe the motor is no good. I have checked the cam timing, valve clearance, fuel supply and glow plugs and it still doesnt start. Next I'll check the IP timing then maybe try to roll start it. If it has excessive blowby I will rebuild it with turbo in mind
(http://i90.photobucket.com/albums/k248/ohospaghettio/IMG_5110-1.jpg)
(http://i90.photobucket.com/albums/k248/ohospaghettio/IMG_5101.jpg)
The car came with a parts car that is actually in good shape, original paint so the rust you see is the rust you get, which isnt too excessive. It just isnt as pretty as the other.
(http://i90.photobucket.com/albums/k248/ohospaghettio/IMG_5112.jpg)
(http://i90.photobucket.com/albums/k248/ohospaghettio/IMG_5096.jpg)
(http://i90.photobucket.com/albums/k248/ohospaghettio/IMG_5099.jpg)
My next purchase is a 020 box, decent springs and shock absorbers, rear swaybar and decent rims/tyres. THat is, if i can get at least one of em running!
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Those are some of the most trashed strut bearings I've ever seen. :wink:
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Would the 92 gas Jetta inlet manifold look something like this?
(http://turbocharge.co.za/shop/images/PIC_0050.JPG)
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It would, I guess.
Anyway, that manifold will be a huge improvement on your TD.
Don't even consider using a stock intake if you have one like that at your disposal!
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same mani i got on my car. good work.. now take off the throttle body, build an adapter, and hook up the boost from the intercooler. i just got my car driveable yesterday with the intercooler hooked up. and let me tell you what, its by far the best upgrade yet. more power with less boost. im gonna put my other fuel screw in later and mess with that a bit. the way this is going, ill be back to a straight pipe in no time.
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now take off the throttle body, build an adapter...
does anyone sell an adapter? can you post pic of yours?
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(http://i229.photobucket.com/albums/ee139/truckinwagen/P4030011.jpg)
(http://i229.photobucket.com/albums/ee139/truckinwagen/P4030004.jpg)
same manifold, just opens on the other side, I had the plate cut out of 1/2 inch mild steel on a plasma table(something thinner could be just as easily cut with a holesaw and/or a cutting torch) and welded a exhaust coupler into it for the intake plumbing.
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i made mine out of some quarter inch aluminum and some thick wall aluminum pipe.
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Do you have to flip the turbo to get this to fit, or can you just bolt it up?
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yeah, the turbo had to be flipped, and the exhaust manifold had to be ground to fit.
I also had to mess with the shift linkage as it interfered with the inlet to the turbo.
I cut the relay shaft and flipped it so it angles down instead of up now, real close fit, but it works.
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with a VNT, it bolts right up :D but if you got any other sort of turbo that doesnt sit down low, you will probably have to flip it. the vnt turbos are already clocked downward facing. you can try flippin the turbo and manifold if you want. ive never tried it, so i dunno if it works.
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thanks everyone for your help.
so far i have an inlet manifold....
I have the option of buying a running 1.6NA motor including injector pump. Is this going to be of any use to me? What are the differences between the NA and TD 1.6?
what turbo should i use for a 1.5/1.6 TD?
Cheers
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if your gonna go with wild boost and power numbers, go with the 1.6.. if you want a few more ft lbs of torque, go with the 1.6. if you want a fairly torquey motor with tons of top end power, go with the 1.5. from my experiences, the 1.6 is ever so slightly faster off the line.. but it seems like my 1.5 has almost twice the top end my 1.6 had.
the 1.6 n/a motors were basically the same as a 1.5, just with bigger cylinder head bolts and a few other slight changes. bore size was even still the same between the two.
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Thanks everyone, the project is slowly progressing from research to procurement.
I have the following parts in hand:
4T gearbox
k-jet intake manifold
1.6TD oil cooler and mount
new shock absorbers
lowered sports springs
alloy wheels with tyres
and have the option of buying the following:
4 bolt turbo exhaust manifold
1.6TD injector pump
1.6NA motor complete with pump
oil supply line to turbo
1.6TD turbocharger (are these easy to rebuild?)
What is the issue with the gasser manifold? is it the clearance between the inlet manifold and the turbo?
Do i need the following?
1.6TD oil pump? are these any different to the 1.6NA oil pump?
ARP head studs?
The main reason I'm considering buying the 1.6NA motor is because i thought that it was a stronger motor for turbocharging. What are the differences between the 1.6NA and 1.6TD? (other than the crank, rods and pistons). Is the 1.6NA head any better than the 1.5?
The main benefit i see is that i can buy oversize pistons for it. Have the supplies of 1.5L o/s pistons really dried up? I would hate to sleeve a block just to have it crack!
Once again, thanks everyone for your help.
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unless you have a quantum/dasher exhaust manifold, or you flip your manifold and re clock the turbo, it will hit the manifold. GTD manifolds go out and up slightly. and mount the turbo up high. ive got a VNT 17 on mine. it comes out and goes down, so the gasser intake fit on there with very little modification.
and as for your questions about the 1.6 engines..
the n/a and turbo engines were quite a bit different. they had oil squirters, notched pistons, oil coolers (witch you already have) and the block and head were actually a different grade of alloy. you should get head studs just because. make it easy on yourself. dont risk cracking a block with stock bolts. the internals of the 1.6 td are almost identical to a n/a motor tho. i would use a turbo oil pump if you can find one tho. ive got one in my motor.
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so now i have a 1.6TD pump, gasser inlet manifold, oil cooler, hopefully a k14 with exhaust manifold and the choice between the 1.6NA and 1.5NA for bolting all this stuff to.
The 1.5NA is very low on compression (roll starter) and the 1.6 is not much better. At this stage I'm leaning towards rebuilding the 1.6 as I can easily find o/s pistons for it.
In the meantime, I'll be put putting around in my other halfs half decent 1.5NA.....
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i just put my turbo pump and injectors on my 1.5, and holy ***.. what a difference. my car used to struggle to go 100, but now you can just get on the pedal in 5th gear and your doing 100 mph in no time. i spanked a toyota solara a couple days ago. pretty sure those are the ones with the supra engines in them.. but needless to say, if you do all that stuff to your 1.5, it will go fast, thats for sure. cause mine flat out RIPS. i drove a newer VR6 jetta the other day, and honestly, i think my car is quicker.