Recent Posts

1

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by vwpieces on Today at 08:33:41 pm »

Did all the coolant hoses I can. Local parts store had all the hoses and even an NOS water pipe In Stock. 
OK, Parts store is in the second floor of MY shop.
Coolant necks and temp senders too.



And a Few more little things.
Injector line clamps, injector return hoses and NOS German Hella oil presure sender.

2

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by vwpieces on Today at 08:24:11 pm »

Moving along... Last couple days work.

New pistons installed. New rod bolts etc.
Head is on and torqued. One notch MLS head gasket...


Intake installed, upper elbow in an NOS 068 from the hoard, rubber hose too.
Exhaust manifold on and torqued.
Didn't fully torque that turbo down, yet. Also need to dig out the correct support bracket for the 171 down pipe.




Moved on to fitting some 1.6TD oil return lines to the NOS oil pan. There were 2 pans, different angle on the fitting on pan and each used a different oil return tube.
Uncrimped the SS braided hose from the required return line to fit this pan. Taller block so it needs lengthening. New hose should be here tomorrow. 3 Otiker clamps at each end will be adequate.
Had to align the tubes.



Decided to use a -4 AN line for the oil feed to turbo. Line and all Stainless steel fittings arrived today. Still waiting for the SS banjo to -4 for top of oil filter housing, Stainless bajjo bolt too. Fitting for top of turbo to AN is steel. SS for that was elusive in my search. Well, did find one in Taiwan for a few bux but wasn't going to pay $20 shipping plus fees.

3

mTDI Mechanical TDI Conversions / Alh mtdi

« Last post by garrettkent78 on Today at 11:44:49 am »

I'm trying to get my MTDI ALH running. It will start, but only run with the throttle fully open. Does anyone have any ideas on what I can check for to cure that?
Thanks

4

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by fatmobile on June 01, 2026, 11:04:03 am »

Those non-AC alternator brackets are hard to find, glad you found one.
I have one with a place a for power steering on the bottom, even more rare.
I'll probably never put power steering in a Rabbit but I can, ha.
 
 I'm going to try to use the AAZ alternator bracket so it has a serpentine belt setup,.. but it will only have 3 holes mounting it because the top right threaded hole is missing on the 1.6 block.
 I just cut the MK1 injection pump bracket short to make the MK1 motor mount:


The AHU alternator bracket has an ear to bolt the extra idler to:
AHUinjectionpumpbracket by vwfatmobile, on Flickr

Good to hear the 1.6 pump will fit that mounting bracket.

5

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by vwpieces on June 01, 2026, 12:34:31 am »

Yes there is another bracket, hiding behind the IP. It does the rear supporting of the IP. And Yes it fits my 1Y block. However that all quickly got scrapped when I decided to try to install the timing cover inner metal.

Last Mockup with inner timing cover revealed I can not use the MK1 1.6 Diesel IP/engine mounting brackets. Now going with a gasser passenger side engine mount and a small diameter hole, cast iron AAZ IP mount. Smaller hole is same as the 1.6 injection pumps. I also flattened the front end of the gasser side engine mount in the press. I was looking for an alternator bracket to hack off the side that goes under the gasser engine mount but didn't find one in the hoard. Considered washers but then just flattened it in the shop press. But I did score a Non-AC Diesel alternator bracket I did Not know I had. I have one on the 1.6TD in the Jabbit but remember needing to source it on that build. Those AIN'T easy to find anymore.
Quickie mock-up, only pic I took with inner timing cover fit and the AAZ small hole IP mount that fits the 1.6L IP.


Blasted and most painted, another mount pressed in that gasser bracket too
Mount press tool and air over hyrdaulic press... like cheating. VW tool number US745




Flattened gasser mount


All blasted and now painted, just need to paint the opposite side of the inner timing cover yet.


And I was real happy to find this mount in the hoard. Didn't know I had it.


New pistons should be here Today! 3:30AM, off to get "some" Sleep.

6

TDI Engine -General Info / Re: gear ratios

« Last post by fatmobile on May 31, 2026, 09:30:32 pm »

Do you know the rest of the code?
There are many different codes for the 020.
 An ABA might have an ACN with maybe a 3.67 ring and pinion that is good for the highway.
Some 02As are better than the 02Js, when it comes to lower RPM on the highway.

7

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by fatmobile on May 31, 2026, 09:24:33 pm »

 Is that the only injection pump bracket you are using?
 I think there is supposed to be one bolted to the front of the block too.

 I'm not sure the bolt pattern on the front of the block allows the 1.6 bracket.
 I believe if that bracket isn't on the front of the block, the belt will probably track off the sprocket.
 The difference between the AAZ and AHU pump brackets is
the one on the AHU has a place to bolt the extra idler pulley that goes between the cam and injection pump sprockets.

 I took some video of the different setups but haven't edited it yet.
 Should have taken pictures.
I have a 1.6, a broken AAZ, an AHU (that's going in a certain grey GTI, yes I still have it) and an ALH block all in the same area.
I might as well do a video on the differences and similarities.

8

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by ORCoaster on May 31, 2026, 05:40:59 pm »

Any hole that size will have two effects.  Less delivery at the same pressure or equal delivery at a higher pressure.  Given the IP has plenty of push that really can't be increased by much, I would say you are going to get less fuel to the injectors compared to the stock 1.6 ones. 

9

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by vwpieces on May 31, 2026, 12:21:31 pm »

Tried searching...
But I did notice the longer delivery valves I stole off an ECO IP have some really small holes. Anyone know if this is ultimately gong to be a restriction point?

Eco DV


And the one off the 1.6TD IP

10

IDI Engine / Re: Franken Build, Need Parts Help 1y and 1.6TD Mixup

« Last post by vwpieces on May 31, 2026, 12:05:58 pm »

This is the nicer set I am going to use. After about 15min in ultrasonic solution.



I went a bit further to blacken or cold blue this set. Also dug up an IP with longer delivery valves and these lines fit perfect.


More Mock-Up and seeing what fits. 028 IM pulley and 068 IP pulley work.




But now to take it all apart and try to get timing covers to fit. I have a funny feeling I will need to use the AAZ IP bracket and Cut off the MK1 IP/engine mount. Todays adventure.

New pistons Will be here tomorrow.