Club 80-90 Forums

ok so ive been gathering bits for a number of years, with the intention of rebuilding my van to a spec that it can pull itself loaded with family and a trailer on holidays. ive been coping with a 1.6na for 9 years now and ive thrashed it fully laiden to gibralter and back(minus trailer). but i can take it no more. I have all the bits for building an mTDI but i wanted to be all flash and go for the flipped box option but i cant bring myself to spend a grand on the conversion kit, or to get my gearbox rebuilt with funky ratios when my windows are falling out, and the rust thinks it has found an Alfa to prey on. I have most panels i need so i might as well use my cash to get my bodywork done.
So when i got a call from a breaker in the a*** end of nowhere saying he had a 1.9td not tdi motor for sale at an extrememly reasonable price i was down there like a shot. Yep it was a TD...... but a 1.6. Very clean, no leaks, new geniuine cam belt and filter,new clutch ect. so after much umming an arring I thought well its the engine it was supposed to have(smoker wise) and had it.
Now once i had it back home i was looking and it has all the pipework for an intercooler(not samco hose, Vw) So is this a 1.6gtd motor from a golf mk2 or a jx. i cant see the code.............hows the gtd differant to the jx? its rated at 80bhp!!!

either way its going in. i had all the bits on another shelf for an aaz swap in case one came along. I should have all the bits i need right? cant find much about cs to js upgrade. any input welcome. should i be thinking about boost pressures an stuff yet? Im excited. looking at egt guages and feeling naughty

well I reckon you could easy get 95bhp from a 1.6 with an intercooler and a nice bosch pump to crank up.

I have an intercooler from a transit,and an oil cooler ready to put on. The good ole k&N and a race can off my old superbike to aid the flow.
Pump wise. mine has 068 130081 i think(poor light) but......... shelf again, i do have a land rover tdi pump. surley thats too much for a 1.6. I dont want it exploding on ma hols!!! not after burnouts, just a nice cookout.

standard pump is usually fine plenty of spare fuelling capacity and you dont need much. I did mine by trial and error. First I adjusted the wastegate to increase inlet pressure and then 1/8 turn at a time I increased the fuelling on the pump and took it for a spin. If you start to get black smoke back it off. On my XUD 9 I increased the air pressure from 0.9 to 1.4 bar. Then the fuelling was increased by about 3/4 turn. After a few test drives I was able to reduce the air pressure to 1.2 Bar and still had no smoke . On towing my 17ft caravan I had a constant light smoke so I reduced the fuelling by 1/8 turn and the result was perfect. Rolling road confirmed I was up from 92bhp (standard) to 112bhp and torque was over 200lb/ft up from 155. An expert would probably do it better than me but it was the fasted LDV pilot hi top I ever saw!!! (bigger intercooler from a rover and the above adjustments worked the magic)