94 Ranger VW 1.6L Diesel Conversion

[Keekee]

Hello all! This is my first post, let alone on a website like this. Did quite a bit of research over the last several months to build a diesel ranger. What I found was

-4BT engines were to heavy
-Perkins are F*!@# expensive
-Izuzu was hit or miss for cost efficiancy
-Toyota diesel...HA!
-Detroit diesels were mostly in Canada and east coast

SO! what I came up with was a swap to a 1.9L VW TDI and after some looking and finding yet again, pants needed pulling down to get one of these engines atop an obscene amount of wiring. After cruising the CL ads, came across a fella with a VW NA 1.6L (he thought it was a 1.9) sitting in the back of his shop for the better part of the last 20+ years... I was skepticle of the $150 price tag that included a complete motor and tranny. However, I took the gamble and turned to be an EPIC WIN. Just some stiffness from sitting but nothing blown, just one stuck cyl where a little rust has formed from an occasional rat home.

After looking at power levels and through hours of the nay-sayers I did find some rays of hope and FINALLY found some dyno specs of a turbo conversion that did NOT dump 20+lbs of boost and obscene mods... this motor with the 5 speed and gearing I have WILL work for what I need it for, just wont burn all 4 tires and I plan to keep my little 31s and just level her out.

Here is where I am now: motor has been torn down and working on the one stuck cyl. Got the head ready to blast and will be doing a port/ polish job. I am blessed with a friend who has a CNC machine if I need, but I will most likely build my adaptor out of plexi-glass and transfer to an aluminum plate.

I am not going to modify the hell out of this thing, I plan to replace rings, seals, ect... the essentials. I will be adding a turno, relocating the oil pump+oil cooler and POSSIBLY some home made oil skirts, intake, ect... I MAY convert to a electronic water pump though... anyone have experience on these?

 

[Maritime Storm]

Keep us updated.

 

[monsterchuck]

From what I know of these, you don't want to push too much boost on a non-turbo motor for durability. And that may be a problem for you, as it's going to be difficult to get more than 90-100 HP without burning something up. My 1999 Golf has OK power, but at it's current power level(stock 90 HP ALH), that engine would be straining to push a 4x4 Ranger with 31's at anything resembling highway speeds. Not saying it won't work, but I think you're going to want more power for drivabilities sake. I'd do a minor overhaul on the 1.6, sell it, and keep my eyes open for a deal on an AHU from a mid-90's VW. Those are almost as good as the expensive-as-all-getout-ALH's, but for some reason it seems you can get a decent deal on them. They do have an electronic pump, but there are several methods of putting a mechanical pump on them. Just my input.

 

[Keekee]

Monster chuck, thanks for the input. I did have my doubts myself but given for what I need this will work. My driving is mostly in town and flat atop the gearing I am using and the fact I don't haul anything with it. So far it's torn down and I'm getting the head worked on as we speak. Buddy of mine works for CAT and is doing all new valve seats and head work. The engine has been CHEAP to Build so far ( about 300$) I had a turbo manifold on its way and gonna run a whopping 5-10lbs boost new pistons rigs and head studs. I have the oil cooler for it and in the next week or so I will begin on having the flywheel machine and get the ate made. I imagine at some point I will run with a 1.9 bunk just intend to have this for my in town cruiser.shes painted cat yellow and coming along beautifully!

 

[greengeeker]

Nice. Glad to see another vw diesel ranger on here....although I think it should be in this forum section?

Here's my TDI Ranger Build. Getting there and hope to be driving it around soon.

I don't think going electric on the water pump is going to free up a whole bunch of hp. Take a close look at your intermediate shaft bearings - they are the common cause for low oil pressure. They're kinda a bugger to replace but with the right tools isn't all that bad. Sound like you have some connections so if you need a drawing for a bearing installer drop me an email.

have fun!

 

[Keekee]

I would appreciate the diagram if you have one. I am not 100% sure yet how to use this site I am still new. My other biggest PIA is the transmission adaptor plate. I have the measurements drawn but Not 100% on the accuracy of the tranny side but I have enough to make a rough template to get it placed and figure out where to go to get it fully balanced so I dont blow my transmission and motor to bits.

She wont be no cummins 12v stacked and over boosted but by god she will get good mpgs and blow black smoke trying to reach 30mph!

BTW, ironically your post is what gave me the idea... happy to be talking!!!!!!!!