VW 1.6 (Turbo) Diesel Modding - TheDieselGarage.com
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Old 09-21-2007, 04:53 AM   #1
JettaLove
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VW 1.6 (Turbo) Diesel Modding

hey everyone i am new....i have been looking around for general mods for my diesel to make it blistering fast haha...well faster atleast... my buddy had a bug that had a TDI similar to mine,it was blowing away anything it lined up against but never learned about the mods....wondering what i need to get sum speed outta my baby....any help would be appreciated
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Old 09-21-2007, 05:16 AM   #2
mckey73
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What year is it? is it really a 1.6? If it's a TDI you can build the crap out of it.
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Old 09-21-2007, 05:28 PM   #3
JettaLove
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it's 1990 Jetta Flair 2 Wolfsburg edition 1.6L Turbo diesel....lol thats my baby
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Old 09-22-2007, 10:16 PM   #4
JD99PSD
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Replace the restrictive rear muffler with somthing straight through (removing it all together and it will drone on the highway, very annoying!), turn up pump, get a dial a boost and install it before the waste gate and turn the boost up... The stock turbo will make 18 to 20lbs wide open. 10lbs is stock, I would go 15lbs maybe. I would do some kind of intake maybe a cone filter, though I have a huge *** filter on mine (the aftermarket one everybody uses on the 7.3 Powerstrokes). I cant say I noticed much difference over the stock air box. My car with 12lbs of boost and the above mentioned mods pully my buddy's 99 TDI pretty well. (his is stock but thats still pretty impressive since its got the variable vane turbo and runs about 20 psi!!!)

Hope this helps
Jason
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'08 F350 Crew Cab 2wd Dually, Custom two toned black over silver, lowered 2"/4" 22" alcoa's w/304/40/22s, SCT Livewire w/RCD tune, flowpro dpf delete.


1984 Volvo 760 GLE, D24T I-6 12v turbo diesel, ARP head studs, MLS head gasket, ported/polished head with 3 angle valve job, turned up pump, front mount IC, custom built T3/T4, monster dura-lite filter, 3" turbo back, WC T-5 swapped, clutchnet 6 puck disc.
Look for it in Diesel Power soon!
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Old 09-22-2007, 10:16 PM   #5
JD99PSD
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whoops double posted
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'08 F350 Crew Cab 2wd Dually, Custom two toned black over silver, lowered 2"/4" 22" alcoa's w/304/40/22s, SCT Livewire w/RCD tune, flowpro dpf delete.


1984 Volvo 760 GLE, D24T I-6 12v turbo diesel, ARP head studs, MLS head gasket, ported/polished head with 3 angle valve job, turned up pump, front mount IC, custom built T3/T4, monster dura-lite filter, 3" turbo back, WC T-5 swapped, clutchnet 6 puck disc.
Look for it in Diesel Power soon!
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Old 09-23-2007, 10:20 PM   #6
JettaLove
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Thanks JD, just one thing how do turn up the pump and change my turbo lbs?

haha and again lots of help i wanna get my baby dun up nice
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Year: 1990
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Old 09-29-2007, 02:25 AM   #7
nfmisso
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You may also want to check out:
http://forums.tdiclub.com/forumdisplay.php?f=4
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Old 01-04-2008, 02:07 PM   #8
malone
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vwdiesel.net is the golden place for VW TDs.

Your 1.6TD is an IDI (InDirect Injection), so check the IDI forum. Here's a link to my 1.6 NA modification post:
http://vwdiesel.net/phpBB/viewtopic.php?t=4391

It's not a turbo version but hopefully the post will help you understand the basic performance enhancements. Then you can start looking at 1.6TD and 1.9TD tuning tips in the FAQ/Tech Tips forum here.

For inspiration here's my old 1.6TD project threads:
http://vwdiesel.net/phpBB/viewtopic.php?t=1352
http://vwdiesel.net/phpBB/viewtopic.php?t=2377

Here's a current 1.6TD project using my old parts:
http://vwdiesel.net/phpBB/viewtopic.php?t=11698

IDIs (TDs) supposedly have better combustion characteristics than TDIs at high RPM, which is very important for HP. Torque is too easy with either engine. With a relatively small aftermarket turbo and stock cam my HP climbed until 5,250 RPM (something a 1.9L TDI rarely or never sees).. it was actually restricted by my fuel pump, which started cutting fuel after 5,250 RPM. The power was amazing with 0% exhaust smoke, with lots of fueling potential. I'm confident the little 1.6L can do 200whp with a proper turbo, fuel pump, intercooler, and nozzles. I had plans for a 6,500 RPM fuel pump (even had a sponsorship offer) but I bought a home so I put all my projects to a halt.

This was also planned but never saw action:


VW diesel modding became popular long after TDIs arrived, thus IDIs were not given a chance for R&D sadly.

Someone installed a VNT turbo from a TDI on a 1.6L TD and the result was a better powerband than a 1.9L TDI.
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Old 01-07-2008, 10:53 PM   #9
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i'm gathering parts and doing a hybrid like you... just haven't got my block yet, i'll have that rebuilt and then getting my 1.9 head done. haha just gotta wait on a slow painter and getting my block. plus i am slow with this stuff also but hopefully i will have it together this summer

:givemebeer
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1981 Jetta Coupe 1.6 Turbo Diesel-plans for a 1.6/1.9 hybrid. lots of fun

1983 Rabbit 4 door 1.6 N/A Diesel and a slush box, awesome daily
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