How do I build a powerful reliable TD?

[MontanaGTD]

I'm starting with a 1.6 Sb engine coded Golf MK2 GTD - I wouldnt mind a 1.9.  But dont know what to start with, what bits are better than othere etc!

please give me a build list!

[rallydiesel]

No power steering, no A/C, no cruise. Use Kolbenschmidt pistons, ARP studs, make sure your block is flat, use metal HG, etc.

[zaprzal]

But dont know what to start with

first: answer yourself a question "how much is powerful"?

[MontanaGTD]

I'm after about 140-150bhp - I've got an SB 1.6 on 150,000 miles and not sure if thats the best place to start or should I star with a 1.9 AAZ bottom end???

[MontanaGTD]

I have no PAS, no cruise and no A/C

[hillfolk'r]

I'm after about 140-150bhp - I've got an SB 1.6 on 150,000 miles and not sure if thats the best place to start or should I star with a 1.9 AAZ bottom end???

id do the 1.9........but thats me
i would also recomend maybe thinking about a TDI-M if you want that much reliable power,since you are sort of starting from scratch anyways
i did a tdi cause i was in the same boat and priced it out and it wasnt too much more to go tdi-m

[myke_w]

somebody's gotta say it-

cheap, fast, reliable - pick 2

No really, I think the stock internals will hold the power back, but I'd go through the whole thing and make sure it's solid, get a valve job, head tested for cracks, leaks, etc. I'd do all new gaskets, seals, o-rings
I think the injection pump is the next place to go, get all the hot mods done to it, no governor, modified advance curve, shaped boost aneroid pin, different cam plate. Then you'll want to select injector nozzles, probably gtd ones, a good free flowing exhaust turbo back (ditch the toilet bowl), you need an efficient inter cooler, a fairly quick spooling turbo. Metal head gasket, head studs, EGT guage, boost guage. Good beefy clutch, 16v pressure plate, possibly a limited slip diff, tires to make it stick, brakes to hold it back.  Gasket with windage tray, good oil pump.

fyi, this is the fast / reliable way

[Black Smokin' Diesel]

I'm after about 140-150bhp - I've got an SB 1.6 on 150,000 miles and not sure if thats the best place to start or should I star with a 1.9 AAZ bottom end???

You can get that out of both the 1.6 and 1.9. The only diff at this point is that the 1.9 has more torque off boost and the 1.6 is a revver.

[MontanaGTD]

"Use Kolbenschmidt pistons, ARP studs, make sure your block is flat, use metal HG"

Where do I get these from??

[subsonic]

read, think, read, think, read, think, spend, spend, spend spend, make, read, think, read, think, read, think, spend, spend, spend, fix, read, think, read, think, read, think, spend, spend, spend, fix, etc....eventually you'll have powerful and reliable   :lol:

Andrew

No kidding.  I have been at this for about 1 year and I still don't have it all together yet. Money, money, money. Now I find out that the Merc turbo I picked is going to be to small.  Only good for around 160hp.  Two steps forward, 1 step back.

[jtanguay]

"Use Kolbenschmidt pistons, ARP studs, make sure your block is flat, use metal HG"

Where do I get these from??

the first can be had from myke_w, arp studs, well contact ARP.  the last can also be had by any parts place, and the 2nd last can be done by any reputable machine shop.

[rallydiesel]

You may also want to do the Peloquin transmission bolt upgrade. The 020 has rivets in the ring gear that can break if your engine is heavily modified. The Peloquin kit consists of bolts that replace the rivets.

You may also want to do the economical 80% slip kit (about $100) or the full on LSD if you can afford it (about $900).

[Gernster]

tell you what I'm going to do, but my primary directive is a smooth, reliable diesel to do lots of miles;

buy a 1998-1999 seat ibiza or toledo TDI (90bhp AHU engine, there are a couple of ebay with damage for £400-£500) transplant the lot using mk3 golf subframe (if I get a toledo its the same) mk2 crossmember, use the cable gearbox and all the wiring.

2.5" exhaust, front mounted intercooler and then get it chipped ( I know it will need to be an overseas chip) to get 120-130. Ill be happy with that and should have a nice smooth economical diesel!

If I sell the bits off the donor and my old bits its shouldnt cost me more than a couple of hundred quid!

[MontanaGTD]

Tell you something else too!

If you get a Toledo - then you can also transplant the dash and the interior - the Td ones also come with 256's on the front and 228's on the back, plus it comes with PAS and ABS!

Just thought i'd throw that in! My maters just transfer a complete Toledo GT running gear etc into a MK2 shell! Its all plug and play!

[Gernster]

so why are you planning on spending shed loads of cash on a 1.6???  :lol: