1.6 and 1.5 talk of making a TDI hybrid.

[JRD]

I've got a similar project in my mind (made a 1.6L TDI engine), so I've made lot of research.

As previously say, you can made a 1.5L TD engine by using crankshaft, connecting-rods and piston from an mk1 1.5L D engine (CR) in a mk2 1.6L TD engine (RA)
The pistons need to be modified to keep place for oil jet.

If you put a 1.9L TD (AAZ) head on this engine, the compression ratio fall to 17,7:1
Cold start may be more difficult. But you can attempt to rev up with more power.
I think it's better to attemp to goal a minimum of 19,5:1


For gearbox, the better choice is a Mk3 TDI gearbox (ASD) who allow you to run near 125miles/h at 4000RPM with a 195/50R15 tire size

[Mark(The Miser)UK]

Are there taller pistons that make up for the 6.4mm shorter stroke when you drop  a 1.5 crank into a 1.6 block?

[JRD]

The 1.5L pistons is higher than 1.6L (44.9-41.7mm=3.2mm, half of the stroke différence)
The other différence is the piston axle diameter (22mm on 1.5L, 24mm on 1.6L) and the crank rod journals diameter (46mm on 1.5L, 47.8mm on 1.6L)

[RabbitJockey]

The 1.5L pistons is higher than 1.6L (44.9-41.7mm=3.2mm, half of the stroke différence)
The other différence is the piston axle diameter (22mm on 1.5L, 24mm on 1.6L) and the crank rod journals diameter (46mm on 1.5L, 47.8mm on 1.6L)

Wrist pin size and rod journal size have no impact on the piston height since regardless of size they still have the same center points. 1.5 piston height is made up for by a combination of a longer rod and a lower wrist pin

[MJF]

1,5 and 1,6 both has 136mm long rods. Difference just in piston.

[RabbitJockey]

I stand corrected 

[R.O.R-2.0]

I've got a similar project in my mind (made a 1.6L TDI engine), so I've made lot of research.

As previously say, you can made a 1.5L TD engine by using crankshaft, connecting-rods and piston from an mk1 1.5L D engine (CR) in a mk2 1.6L TD engine (RA)
The pistons need to be modified to keep place for oil jet.

If you put a 1.9L TD (AAZ) head on this engine, the compression ratio fall to 17,7:1
Cold start may be more difficult. But you can attempt to rev up with more power.
I think it's better to attemp to goal a minimum of 19,5:1


For gearbox, the better choice is a Mk3 TDI gearbox (ASD) who allow you to run near 125miles/h at 4000RPM with a 195/50R15 tire size

how come nobody else can come up with a 1.6 TDI?

is it a direct injected 1.6? it uses a TDI head?

not just an IDI engine with a turbo, right?

there IS a difference between a turbo indirect injected engine, and a turbo direct injected engine..

[Alcaid]

how come nobody else can come up with a 1.6 TDI?

VW has done it I have a 1.6 TDI (Common Rail, 16V) in my 2010 Passat

[R.O.R-2.0]

how come nobody else can come up with a 1.6 TDI?

VW has done it I have a 1.6 TDI (Common Rail, 16V) in my 2010 Passat

ok, let me re-phrase that..

nobody has come up with a hybrid TDI out of a 1.6 IDI block, and 1.9 head, with custom pistons.. prothe was trying to invent one..

im not speaking of brand new euro parts that we can only dream of in north america..

[R.O.R-2.0]

http://www.vwdiesel.net/forum/index.php?topic=24795.msg267762#new

clicky!

thats not a 1.6 16v TDI..

thats a hybrid.

THATS what i was talking about..

[Alcaid]

Except that that would require fully custom rods (you cant drill out the little end from 22 to 26mm) and that there is no way to modify a TDI head to increase compression as it is flat and the compression is set by the piston bowl volume on a TDI piston.

[R.O.R-2.0]

plain and simple, a 1.6 TDI can not be easily built out of VAG parts.. nothing will fit together without HEAVY modification..

if i were going to try and do something, i would re-bush the pistons to from 26mm to 22mm.. that would work.. drilling the rod 20 26mm will not.

but still, theres no combination of pistons/rods/cranks/blocks to do this easily..

[Mark(The Miser)UK]

plain and simple, a 1.6 TDI can not be easily built out of VAG parts.. nothing will fit together without HEAVY modification..

if i were going to try and do something, i would re-bush the pistons to from 26mm to 22mm.. that would work.. drilling the rod 20 26mm will not.

but still, theres no combination of pistons/rods/cranks/blocks to do this easily..

Ha you beat me to it. I was going tosuggest a composite bush. The two standard  bushes must surely be a close fit, ie the i/d of the 26mm bush can't be far off 24mm

[theman53]

I split this so that we could continue discussing.

I would really consider seeing about custom pistons for the 1.6 into a TDI. Does anyone know who would tackle this? I would do a 1.6 TDI for the next install into my Jetta if I could get pistons for under 800. USD Heck maybe more. I had 1600.00 in the machining, hard parts, and aquiring the long block that needed rebuilding...my labor was free. I really don't want to do that again and have a precup fall out, but I REALLY miss the performance of my 1.6.