HOW TO: VW 1.6L turbo diesel POWER UPGRADES

[@caddy-co]

I have a 1.9 sdi but I'm hoping this will help me understand it better. Glad I found this.

[@OliverFetter]

Hell yeah!

[@bryceribken183]

I was really hoping you would make this exact video. Great synapses of your whole build and super useful suggestions. Great job 👏

[@OliverFetter]

Hell yeah! Glad you found it helpful 😁

[@Rene-z2s]

Please help on how to create the intake as the one You have.

[@chrisladouceur4093]

Would also like to know what was used

[@firstname0126]

You are the goat. I just bought a 1.6 td. I was hoping I could get a decent amount of power that’s reliable. Something that’s surprisingly fun on back roads and I can take on bigger roads and get good gas mileage. Do you know if a mk4 5th gear conversion would fit in a mk2 trans?

[@OliverFetter]

Thanks 😁 I have no idea. The mk1/mk2 manual trans is the 020. If it fits 020 you'd be good to go.

[@firstname0126]

@@OliverFetter great, thanks

[@PAPAwheelie568]

Garrett gt15 and stock 9mm pump head fuel screws maxed and AFM maxed out on around 26 psi with a very efficient intercooler and full 2.5” exhaust on the dyno I made 97hp at the tires that was my stage 2 I’m no upgrading to a 12mm pump head and cam plate out of a 1.9 that has been welded and added onto for extra lift and I should be getting my 1.9 head by then and I’ll have my hopefully 200hp 1.6 Frankenstein build. Keep up the work!!! Ps on the 200hp build I’ll be running compound turbos and running water methanol injection to help out a touch. We should Colab some time could be exciting!?!?

[@OliverFetter]

Heck yeah that sounds like a sweet project. Id be down 😎 lmk

[@DIYWilly]

Excellent video! I have a 1.6 Turbo diesel in my Suzuki Samurai and it needs a new fuel injection pump. With the ARP head studs you mentioned, does it change the torque process? Or does it stay the same. I been watching all you videos again to help with my repair. Been thinking about a Giles pump but?? Thanks again for sharing your knowledge!!

[@OliverFetter]

Hey thanks! That sounds like a sick setup!! The torque pattern remains the same but you split your total torque # into 3 equal steps - (I forget the spec atm but let's just say 100 ft-lb is finishing torque) then you'd do 33, 66, 100 to help the gasket "flow" evenly. Could always try tuning it yourself first 😉

[@DIYWilly]

@@OliverFetterI may try tuning it myself but first I need a replacement pump. My pump is done.

[@ChrisGR93_TxS]

i had an etka book with all the vw engine specs from 80something -91 and there was a 1.6d turbo on a t3 that had if i remember correctly stock power of 70 or 80hp ~60kw was a 2 letter engine code , i cant find the book anymore , it was rly small and probably lost it somewhere ( i remember had engine codes/ kw/Ltr/ cylinders/year/model/and for what country)

[@angusdewar5933]

There was a 1.6 TD with a Garret t3 that I believe came in an Audi 80. I do have the turbo which over here is rare as anything but it has a crack in the exhaust housing

[@philippeichinger3246]

The T3 had the JX engine code Simple garret charger and it made 69PS

[@philippeichinger3246]

In the audi 80 b3 ypu also had the turbodiesels Some even came with an i tercooler from stock and made 80 hp

[@bertawarwagon08]

Great video just getting my 85 Jetta I bought blown up in a field back on the road with a rebuilt engine but regretting not doing the arp studs now I see this lol but helped me a bunch with picking a new turbo as mine is passing oil

[@OliverFetter]

Thanks! Hell yeah sounds like a good project. Glad I can help 🤓

[@bertawarwagon08]

@@OliverFetter that turbo mentioned is it sized good for a daily driver ?

[@OliverFetter]

@@bertawarwagon08 Id daily any of the turbos lol but the GT2052 is a nice all around size. You will need sufficient fuel to make it spool & feel snappy but that's well within a light tune on an unmolested pump 👍

[@Draxterwav]

Very interesting video and alot of useful informations nice bro

[@OliverFetter]

Thanks!

[@skythetimelord]

I appreciate the entire video i know you said muddled through but this gives me enough info for me to stick with the diesel i have instead of swapping it out Unsure if i just haven't done enough digging before but this video is what ive been looking for since 2020 time for me to draw up a plan and grab a wrench 🔧

[@OliverFetter]

😃😃😃 let's go!! I'm stoked it did that for you. I have long been chasing the fast diesel experience and it's definitely out there and it's definitely rewarding 🌞 thanks!

[@skythetimelord]

Honestly I had lost hope it was possible mostly cause I didn't know where to start. So I thank you 🫡

[@EnGammalAmazon]

I have a stock NA 1.6. I found a 1.6 turbo manifold and was planning on going with a slightly larger turbo. I just upgraded my stock ALH VNT 15 with a new VNT 17. Would the older VNT 15 assembly fit the 1.6 head? Would I need to do some porting on the exhaust side? I will not be using the 1.6 in a car, but using it for powering a stationary hydraulic power unit for my sawmill system. Any thoughts? I don't really need a turbo on this, but.........since I do have it........

[@OliverFetter]

First, that's super cool!! Hell yeah. Turbodiesel sawmill 💪 secondly yes it'll fit right up, no porting or anything needed. You may have to play with the vacuum system for the VNT to work but it sounds like you're well equipped to play with such things!

[@EnGammalAmazon]

@@OliverFetter Thanks for the help. I've been building equipment, vehicles and anything mechanical for over 55 years. There is just about nothing I will not tackle! By relocating all of my mill's hydraulics to a standalone pump system it leaves me more HP to spin the bandsaw head. When I get my cars to Sweden, I am pulling apart the VW Golf with the built ALH and putting it into my 1966 Volvo Amazon wagon. It will be mated up to a Toyota W-57 five speed overdrive trans and going into the stock Dana 30 with 4:10 gears. The ALH should be putting out about 190 HP without any major tweaking of the systems. It should be all around fun with the TDI Volvo wagon. I have three Amazons going to Sweden with me. Keep up the good work. I'll be watching.

[@OliverFetter]

@@EnGammalAmazon let's go!! That sounds sick 💪💪 appreciate it!

[@jesperkonstmann2114]

the 1.6TD 1V engine 60 HP came with KKK K14 turbo or Garrett T2 the small eco turbos. The fun turbo´s is from a JR engine 70 HP thise came with KKK K24 or Garrett T3 these turbos are somewhat larger and are a good plug and play if you have a 60hp engine and you want a bit more powa bebeh. i like this channel it som good stuf you pump out and good detailes about diesel tuning😉

[@OliverFetter]

Thanks! I appreciate it! That's interesting. I havne't spent much time with the OEM turbos on the 1.6 because it was cheaper on my first motor to buy a rebuilt garrett than it was to rebuild the kkk14, never went back!

[@jesperkonstmann2114]

@@OliverFetter I understand, there isn't much push in the little k14 either. so it's good to try something else, it gives good inspiration for alternatives on the 1.6 engine, what it can spool up etc. i am hooked on the new VNT set up you have made, damn the old td is flying now. :D

[@OliverFetter]

@@jesperkonstmann2114 hell yeah thank you! I'm excited to see what else it can do, it's not quite polished yet

[@MillersMotors]

Very thorough!! Good info in there

[@OliverFetter]

Glad it was helpful!

[@KaseyVerkamp]

Do you know if there is a bigger or better nozzle for the injector

[@OliverFetter]

I think in theory there are bigger nozzles (maybe from black forest industries?). What I've *read* (ie it may not be true) is that the stock nozzles actually flow plenty. I haven't had an issue with them yet so I guess it's kind of confirmed 👍

[@KaseyVerkamp]

@@OliverFetter thanks for the great feedback, I love you videos lol

[@OliverFetter]

Thank ya!!

[@chrisladouceur4093]

Speaking of multi-layer head gaskets… any suggestion?

[@OliverFetter]

If mechanical head: only custom available, don't bother, if hydraulic head : definitely buy a 1.9l (AAZ) mls head gasket

[@chrisladouceur4093]

@@OliverFetter yeah I’ve got a hydro head. Does that fit good tho? No change with compression?

[@OliverFetter]

@@chrisladouceur4093 yeah you'll be in good shape as long as you order the correct thickness 👍

[@chrisladouceur4093]

Would it make sense to bolt an O2J onto this?

[@OliverFetter]

I think maybe eventually it would be worthwhile? From what I understand they have longer gear ratios & can handle more HP, I don't think a 1,6 would really break an 020 but the longer gears could be nice eventually if speed is the aim!

[@chrisladouceur4093]

@@OliverFetter any recommendations on changes to gearing for the 020?

[@OliverFetter]

@@chrisladouceur4093 I know you can put in a longer 5th gear 👍 helps with high speed revs. I haven't dabbled with any transmission modifications myself yet but I think I'm headed there soon

[@chrisladouceur4093]

@@OliverFetter I do a fair bit of highway travel for work and a longer 5th gear is definitely in mind. Thanks for the great content!

[@OliverFetter]

@@chrisladouceur4093 no problem 🌞 anything in particular you'd like to see covered on the channel?

[@domdoesgaming7748]

I can pay for shipping and for it to be made I’m taking my 85 to cool April nights and need and want to put a good looking hood exhaust. And I like yours.

[@OliverFetter]

Right on 👍 chat.whatsapp.com/IaFDSRFX85pAfoIy23oJqu

[@DanMay-qo5re]

What is the engine code on your casting. I have an 81 na and I’d like to build a 1.6 turbo. Just curious on which casting to seek out

[@OliverFetter]

Ngl not sure which number you are after! Give me the location on the block & I'll see if it's readable

[@tomaspinto7079]

Which head and plunger do you use? And what is it out of?

[@OliverFetter]

11mm pump head from a vw 1.9 TDI injection pump 👍

[@dwscooter]

@@OliverFetter i was going to ask about this as well. but which 1.9? do you remember the engine code? how much extra power will a 10mm do? mine was doing well on a recent trip from illinois, through missourri and into oklahoma. but by getting to new mexico, power was dropping. before albuqueque, i had to trailer it back home. i'm putting things back together now. governor mod will have to be done for the hills/mountains. this is in a vanagon with a rabbit engine. early CY engine code.

[@dwscooter]

i'm surprised that with all the mods mentioned, you stated hp at only around 100 to 125 HP. but for the head bolts, absolutely toss out the stock ones. i was on my home once when i heard a whistle. "what is that .............. ahhh shit!" 🙂

[@rashdecisions523]

Hi, i have a 89 Golf 1.8 petrol auto..... looking for more performance and better mpg.... I've been offered a pd130 diesel engine conversion and wondered how that would behave with my current 3 speed auto gearbox.....any advice would be appreciated, thanks 👍🏼

[@OliverFetter]

Hey! I know my 020 5 speed straps up to a ALH (PD110?) motor, so I imagine it would be the same with the auto. I can't speak to how it will stand up with the power or gear ratio wise... Never had an auto in the car!

[@BerzerkerGarage]

What 1.6l did you use?

[@OliverFetter]

Currently in the car is a 1983-ish 1.6L turbo block with a mechanical head 👍

[@BerzerkerGarage]

@@OliverFetter so it is the one after the 1.6l IDI (NA)

[@OliverFetter]

@@BerzerkerGarage yes, still idi, still mechanical, but designed to accommodate a turbo from the factory.

[@BerzerkerGarage]

@@OliverFetter so I would have to swap the motor to get a turbo? Thank you. Great channel.💪

[@OliverFetter]

@@BerzerkerGarage thanks! depends, what motor do you have?

[@gulfy09]

Btw what oil do you use

[@OliverFetter]

For now, 15w-40 non synthetic. I rarely make it to an oil change intervals before something breaks lol so it's not worth the extra $ on synthetic in my particular scenario. I have run synthetic in the past & didn't see any noticable improvements.

[@braydonsnell8791]

Awesome video man, I'm a long time diesel guy and alot of what you mentioned translates into what i do here in Australia with our TD42 nissan patrols. Unfortunately there is the stigma that you have to pay somebody to do it right which has really killed any knowledge or creativity but theres a few of us that stay away from workshops and try to better our knowledge as best we can Really good video regards from 🇦🇺🤙

[@OliverFetter]

Hey! Cheers to that 🍺🍺🍺 sounds like fun stuff to be building! Definitely keep it up, so much to learn :) Appreciate it!! Best of luck from USA

[@OliverFetter]

Here the diesel rabbits are generally considered less desirable than the gas versions bc they are low-power from the factory but with a bit of tuning they really sing down the road 😁

[@braydonsnell8791]

@@OliverFetter little do they know, 😝 so much potential i've got a 1.6 non turbo engine in my shed that looks mighty buildable now after watching your videos on them

[@OliverFetter]

@@braydonsnell8791 😁😁😁 hell yeah!

[@Rene-z2s]

Hi. I have a 1.6 TDI. I Would like to have a help. On how to create the intake please... I am doing everthing You advice. Please help My friend. I Would like to have the same intake. Or there is a way You sale the intake.

[@OliverFetter]

Hi, I didn't make it lol it's from Profi Diesel

[@Rene-z2s]

@@OliverFetter lol. Don't worry still You are My hero... Si Will continue learning from You

[@OliverFetter]

@@Rene-z2s 😂🥲🥲 let's go! Haha

[@BEYTEK]

hasha yahhh boiii

[@BEYTEK]

loved your explinations buddy, your tight EMAP pressure is very important. Im compound turbo, Still learning but emap is key. My 1.6 Diesel will probs just have fuel pump tweeked slightly on the stock turno with intercooler :)

[@OliverFetter]

Hell yeah!! Glad it was helpful

[@RobertSchmitt-u7l]

Scrap it, import european

[@OliverFetter]

Not sure how that's an upgrade 🤔

[@KaseyVerkamp]

Do you know if there is a bigger or better nozzle for the injector