My 1.6 project,,

[TUFFY]

Wouldn't I still need a smaller exhaust housing on the TO4 even on a compound setup? The turbo is off a engine of probably 400 cubic inch or more. I don't know what housing is on it now.

[TUFFY]

Also how much boost will a stock shortblock handle?

[RabbitJockey]

Yeah I'd still try and stay on the big side of t3 stuff like a .63 since spool up shouldn't be as much of a problem ull have plenty of loading haha

[TUFFY]

Hi, has anyone ever put a M.B. 240D inline pump on a 1.6 VW? Would that be a option for what I am doing? I would think the inline pump would give me a better pump than the VE pump.

[RabbitJockey]

Andy2 has one on his compound 400+hp tdi, it is indeed a better pump, ive never seen one on a 1.6

[R.O.R-2.0]

Hi, has anyone ever put a M.B. 240D inline pump on a 1.6 VW? Would that be a option for what I am doing? I would think the inline pump would give me a better pump than the VE pump.

the VE is good for ~200hp in STOCK trim..

[RabbitJockey]

Yeah but those inline pumps allow for more revving, more fuel too but that's not really needed haha

[TUFFY]

At what boost do I need stiffer intake valve springs? So boost don't hold open the valves.

[Blocksmith]

Hi, has anyone ever put a M.B. 240D inline pump on a 1.6 VW? Would that be a option for what I am doing? I would think the inline pump would give me a better pump than the VE pump.

the VE is good for ~200hp in STOCK trim..

Just a couple thoughts--

I don't think I've heard of anyone getting 200hp without a Giles pump, and I dunno if I'd call a Giles pump 'stock trim'  .. provided we're talking about a 9mm pump, that is. I'm sure 200 is nothing for a 11 or 12m; heck, maybe even a 10mm pump. But you did say this was a low budget project, so I don't know if a 11 or 12mm pump would be outside the budget. If you're going to have to modify the VE significantly to get the fuel and rpm potential you want, then it just might be cheaper to find a merc pump, which would flow way more fuel than you could use, and rev higher to boot, right out of the box. Only obstacle would be finding one for reasonable, and then making it fit. I'm definitely going to yank the first one I see at my local pull-a-part; walking out the door with ANY injection pump for a measly $40 flat rate makes me feel like a professional thief     So far the only merc pumps I've seen are 300D pumps though 

If revs are the primary concern, while the inline pump will be able to turn more revs than the VE in stock configuration, this is true, I've also heard tell of people getting up to 7k out of the VE pumps, though, so don't count them out completely. Using beefier plunger return springs is the key, I believe. I, too, am dissatisfied with the low rev potential of the stock 1.6 IP--I'm working on modifying an 11mm plunger & springs to run with a 1.6 camplate; looking for over 6,500 to shut up some of my gasser buddies  . 

[R.O.R-2.0]

Hi, has anyone ever put a M.B. 240D inline pump on a 1.6 VW? Would that be a option for what I am doing? I would think the inline pump would give me a better pump than the VE pump.

the VE is good for ~200hp in STOCK trim..

Just a couple thoughts--

I don't think I've heard of anyone getting 200hp without a Giles pump, and I dunno if I'd call a Giles pump 'stock trim'  .. provided we're talking about a 9mm pump, that is. I'm sure 200 is nothing for a 11 or 12m; heck, maybe even a 10mm pump. But you did say this was a low budget project, so I don't know if a 11 or 12mm pump would be outside the budget. If you're going to have to modify the VE significantly to get the fuel and rpm potential you want, then it just might be cheaper to find a merc pump, which would flow way more fuel than you could use, and rev higher to boot, right out of the box. Only obstacle would be finding one for reasonable, and then making it fit. I'm definitely going to yank the first one I see at my local pull-a-part; walking out the door with ANY injection pump for a measly $40 flat rate makes me feel like a professional thief     So far the only merc pumps I've seen are 300D pumps though 

If revs are the primary concern, while the inline pump will be able to turn more revs than the VE in stock configuration, this is true, I've also heard tell of people getting up to 7k out of the VE pumps, though, so don't count them out completely. Using beefier plunger return springs is the key, I believe. I, too, am dissatisfied with the low rev potential of the stock 1.6 IP--I'm working on modifying an 11mm plunger & springs to run with a 1.6 camplate; looking for over 6,500 to shut up some of my gasser buddies  . 

everybody on this forum, whos been here a while, only needs to hear 2 words, and instant thoughts of 195hp (on a 9mm VW injection pump, mind you!) come to mind...

Dave Cross...

the mastermind behind Passenger Performance..

his special intake manifold, and i dont remember what turbo, but 195hp on a basically stock pump..

and you would have better luck trying to turn high RPMs with a 10mm plunger..

i doubt a 11mm plunger would turn that fast without seizing up, and breaking..

Jeremy knows a thing or 12 about how fast a plunger can spin before it commits suicide..

[Blocksmith]

Yep, read that thread, pretty sure that was indeed a Giles-powered hunk of solid awesomeness...I mean, unless he took it off later, which I don't recall being the case. I still stand by my belief that if Giles has touched it, it's gonna be waaaaay to schweet to be called anywthing close to stock  . And yes, I want one, someday, when I can afford it 

http://www.vwdiesel.net/forum/index.php?topic=11698.30

Sigh, so I work a long day, 7 am to 9:30 pm, stoked I have a couple hours to work on my car, get everything hooked up ready to start it, no fab yet but wanted to hear it idle. No fuel at injectors... solenoid is sticky, put another used one in that worked fine, tested it in and out of the pump, its all good. Still no fuel to the injectors. Filled the pump, filter and lines with fuel, nothin.

I think the vanes have seized up from sitting for so long or something. This is  Malones old Giles stage 4 pump from a couple years ago, only ran for a couple thousand km's, than stored with diesel fuel since than... Tomorrow night I'll steal my buddys hand pump from his outboard motor on his sailboat and get that on the inlet of the pump, dunno if its gonna help much. Damn really wanted it to fire tonight. :evil:

Anyone got any tips for freeing up sticky vanes?

Turbo is a big t3/t4.
Pump is a giles pump with 9mm head, plannin on gettin a bigger pump but want to get this up and running first to see how much more fuel I need.
Clip on timing cover is from mk2 td's
Not worried about the holes, I don't drive through 3ft deep of mud
What are ya meanin by momo's?

We'll see how the headgasket stuff goes, I am hoping with the extra porting, manifolds, bigger turbo etc, the hg issues will be less due to better flow and pressure distribution.

Yeah theres a lot of parts from different cars here
 :lol:  Thanks to all my friends like Mark, Erik, Brett, Keegan and all for helping out and donating trading parts etc!
 
The fittings on the manifold are for boost gauge, wastegate and lda like trevor said.
Black widow... I like it! black and red is one of my favorite color combos. I used to smash those spiders to bits when I was a little kid.

Power steering- already deleted

[TUFFY]

240D pumps show up on ebay for what I would call a decent buy it now prices, granted they are high mileage pumps.

[TUFFY]

Hi again, If I do compound turbos can I use the Porche K26-6 turbo I have and use a TO4 as the big turbo? If it will work about what size exhaust housing would I need on the TO4?

I also have a banks turbo from a 6.2 GM diesel. Looks the same as a TO4 but has a much bigger than 2" inducer than I am limited to. I assume that exhuast housing would be to big also on a compound setup. I would have to dig out the turbo and see if the housing has any ID on it  for size.

Also how would it be to keep the turbos spooled if RPM pulls down during a pull?

I have read the stuff on the car that made 195hp at wheels with small pump and T3/T4 turbo. That is what led me to this site. Lots of good info on this site.

[TUFFY]

Banks turbo has a 1.00 exhaust AR

[Jetmugg]

Awesome project there.  I'm building a 1.5 turbo VW diesel engine that's going into a Dodge Rampage, also for a racing application with a 1.5L displacement limit. 

I also have a good bit of experience with MB diesels.  Let me give you something to think about, with respect to the MB's.  The 240D (OM616, I believe) engine is OK, but was phased out and replaced with the OM601, 602, and 603 series of engines which are lighter and more modern.  These are the 2.2L 4 cyl, the 2.5L 5-cyl, and the 3.0L 6 cyl.   These engines would have been in MB 190D's, and 300D 2.5T's from '84 to '95 (or so, depending on the models) in the USA.  They were available in other models outside the US.  These engines have a lot of performance potential - do a youtube search on OM602's in particular.  They use the Bosch inline pumps, and with the right pump and turbo setups, can make many hundreds of HP.  Your budget becomes the limiting factor.  Later versions of the same engines use dual cams and 4 valves per cylinder.  These are the OM605 and 606, and have even more performance potential. (again, not all engines were available in the USA)

  I'm curious about the intake setup on your VW - can you share any more photos?  Is it completely fabbed from steel?

SteveM.