can a 1.6T bottom end marry to a 1.5 top end?

[VWSmokr]

NintendoKD, if you still want to get a rebuild kit, Turbo City  http://www.turbocity.com/  sells them. They have a good reputation with many folks for rebuilding, and will do some switching/swapping, I understand. They may even cut you a deal to swap for a more appropriate-to-diesel-use turbo, since most of their business on the small turbos is probably with the ricer gas-burners. They're @ 137 W. Katella, Orange, CA 92867 phone: 714.639.4933. Seem like good people & knowledgeable, though I haven't a whole lot of business with them yet.

Hopefully in the near future, I'll be putting together a 1.6TD in a 1.5 block, and, due to costs and availability, I may just use a cherry 1.5N.A. head, with some heat-rejecting coatings appropriately applied to combustion surfaces, valve faces, and exhaust ports. The block already has had piston squirters installed, and the 1.5 pistons have been notched for them, as well as the whole rotating assembly balanced(Rev-Power). I will coat the piston tops, and am using head studs (from RaceTech). Even though it will have an air-to-water I/C, I don't plan on running much over 10-12psi. This project is about economy and clean running, not raw power.  Currently the car has 2.25" exhaust all the way back (big difference, even with the N.A.), and I have a very short glasspack to install on it if it's too loud running open after the turbo.

Best wishes with your engine build.

J.R.
SoCal

[Rabbit on Roids]

NintendoKD, if you still want to get a rebuild kit, Turbo City  http://www.turbocity.com/  sells them. They have a good reputation with many folks for rebuilding, and will do some switching/swapping, I understand. They may even cut you a deal to swap for a more appropriate-to-diesel-use turbo, since most of their business on the small turbos is probably with the ricer gas-burners. They're @ 137 W. Katella, Orange, CA 92867 phone: 714.639.4933. Seem like good people & knowledgeable, though I haven't a whole lot of business with them yet.

Hopefully in the near future, I'll be putting together a 1.6TD in a 1.5 block, and, due to costs and availability, I may just use a cherry 1.5N.A. head, with some heat-rejecting coatings appropriately applied to combustion surfaces, valve faces, and exhaust ports. The block already has had piston squirters installed, and the 1.5 pistons have been notched for them, as well as the whole rotating assembly balanced(Rev-Power). I will coat the piston tops, and am using head studs (from RaceTech). Even though it will have an air-to-water I/C, I don't plan on running much over 10-12psi. This project is about economy and clean running, not raw power.  Currently the car has 2.25" exhaust all the way back (big difference, even with the N.A.), and I have a very short glasspack to install on it if it's too loud running open after the turbo.

Best wishes with your engine build.

J.R.
SoCal

i would do the exact opposite dude. take a turbo block and dump a 1.5 rotating assy in one. instant high revving, more boost friendly engine. bolt an AAZ head on top too, then you might have something worth while. 1.5 blocks are just so weak.. they are like, stupidly weak.

[maxfax]

And once again a 1.6 rotating assembly under a 1.5 head makes the compression high..   Throw some boost at it and you'll see how weak that block is...


X2 about Turbo City though...  Been very happy with them.

[NintendoKD]

sooooooo.. anyone got a 1.6 td block for me?  local would be nice, still in the market for one, theres money and a perfectly good "non-cracked" 1.5 block in it for ya too I want the td block because of the oil squirters. any takers tried craigslist and stealbay, I have other stuff too like the stock diesel intake mani, t61 greddy tc, and LOTS! of interior mk 1 parts from my 78 gasser

[RustyCaddy]

Jack at VW diesel parts said to use a 1.6 liter head gasket when I got the oil return reducer and gasket from him; not the 1.5 liter headgasket.

i have a 1.5 head with head studs on a 11mm 1.6 liter block...ready to install.  I have read the compression should be 25.3:1 instead of the usual 23.5:1 for a 11 head/block.  All i am needing is a dependable commuter with good mpg; Jezz...i hope this thing works out .

[Rabbit on Roids]

what the hell is the difference if you use the 1.5 or 1.6 gasket? they are both made from the same thing. FIBER

[RustyCaddy]

The 1.5 liter gasket is made for the small owl return opening so when it is fitted to the large oil return opening of the 1.6 liter block the extra fiber of the headgasket is exposed at the interface and maybe breaks down overtime...i think this can be an extra source of gasket failure....you'd have to ask Jack for more info cause he is the man selling the oil reducers.  i thought i would use the 1.5 liter gasket and he corrected me.

[maxfax]

Rusty pretty much has it..    Actually the hole in the 1.6 gasket is just plain too big for the 1.5 block and head.. Or the 1.5 gasket is just too small for the 1.6 block and head... Here's a fizzy pic of a 1.6 head with a 1.5 gasket sitting on it.. Note the very slight gap where the arrow is pointing...