Part 1 The Block

[ShoulderMan]

Hello. My name is Ron
 
 After buying a Diesel VW, and having it die on me., I have found your site. So far, this is the best form I have been on for information about the IDI engines. After  searching and researching, lurking and asking questions, here and there, I want to share my story with you all.

      My story begins with a 91 Jetta Diesel I found for sale, that fit the bill. I bought the car with a knock, It knocked for 2 days and a night, then at 2 am in the morning, she dropped a valve.  Took out a piston, Rod, and munched the Head. So much for saving money.  :cry:
 
So, I decided that the engine needed to be rebuilt.  I figured, Not bad for having 300K miles on her. After finding out what a head would cost, I found a used 1.6L for the same price. So I bought that,  then took it apart, and decided that I no longer wanted to use that, but I wanted a turbo diesel.  That lasted for about an hour. Untill I found out how much those go for. So, I pulled the lower half of the engine in the Jetta out with the Transmission that would NOT let the engine leave with out her.
   
 Back to vwdiesel to see what I could do.  seems that a TD is the only way to go. and everyone who is anyone has one.  
 So I said what the hey. Some say it cant be done, but my pocket book says it can. (At least the plastic in it says i can try)
 
Off to the Shop both blocks go. Both to be cleaned up. but only one to be turboed. I had them drill and tap the holes for the oil squirters,  and check everything else. I will be using the 91 block out of the Jetta.
 
I dont quite know where I am going with this project yet as far as
Power vs MPG. So far this is what I have, or what is on order.

 Bentley Manual
 Kolbenschmidt .50mm over Pistons
 Total Seal Rings
 Pauter Rods
 ARP Hardware
 Main Bearing Girdle
 Oil WIndage Tray
 Bosch Turbo 1.6L Injectors

I still need
 Bearings
 36mm Oil Pump
 Gaskets
 Modified Oil Pan (Or Dry Sump)

 The Rods im told will not be done untill January. about 2 months after the order is placed.  Thats If I can get Don a good rod and a piston over to him, before the month is out.  
 
 Does anyone know a good oil pump to buy. There are a lot out there rainging from $30.00 to $180.00. ? all for the 36mm pump.
 I figure Clevite for the bearings, and dont know who for the gasket set.
   Then the  price for a modified stock oil pan that you can buy for $30.00 stock is $380 modded. I figure I can do something like that myself. or go with a dry sump system, before I pay for one modded.

 Also, After buying the ARP head studs and main studs, I bought the Girdle which comes with new ARP studs to fit. (and they want 20% to restock)  Im also wondering if anyone has done or thought about using larger head studs, like in the Cummins.  14MM?  If they would work, That should help keep the Head from blowing or letting go, at least for a little while longer? No?

Thank you for all your help,
-Ron

[53 willys]

sounds like a sweet build!
I like getting my parts from "Myke_W" from here on the forum..fast shipping and good quality parts.
http://www.vwdiesel.net/phpBB/profile.php?mode=viewprofile&u=798

I thought all the NA blocks already had squirter holes?...you just needed to buy the squirter nozzles??

I think 14mm studs would be to big... not enough block material on the corner studs and the studs next to the big oil passages...?

[TurboJ]

Very nice parts list! You should go a long way with that stuff.

Where did you order the Pauter rods and what are they going form, if you don't mind me asking?

[theman53]

I think your on the right track, just listen to everyone on here but me.
I don't know as I have never had one that new, but I thought sometime around 90 the diesels were all the eco. Probably not, but if so they all had the oil squirters. If it is the eco they were the full turbo motor except the boost fueling on the top of the IP.

[ShoulderMan]

I will be buying the Rods direct from Pauter in Calaforina.  The rods have went up in the last month from $709 to $795, plus $45 each for the EDM mod.

 My bolck did not have the holes for the squirters, but the space was already there waiting to be drilled.

 I will post up some pictures as soon as i can.

[53 willys]

there was talk of bigger head studs in here...
http://www.vwdiesel.net/phpBB/viewtopic.php?t=2538&postdays=0&postorder=asc&start=0

[gigaz2]

rods are not that important in IDI applications, stock ones are good for a lot of punishment

[lord_verminaard]

Don't get clevite bearings, at least not for the mains.  I think Glyco is the only kind that come with the separate thrust washer, the rest of them have the integrated washer which is junk.  I'm going to be ordering a bunch of bottom-end stuff from Myke here very soon.  He sells all the good stuff.  I'm only getting OEM head bolts (it is the Wife's car after all.. ) But I am going with a metal head gasket, full gasket kit, all new bearings, and oil-pan gasket with built-in windage tray.  Fortunately, I didn't need new pistons, just rings.  Your build sounds great!  Can't wait to see the results.

Brendan