aaz into a mk1 cabrio build

[giulianot]

Today was a great day! I made it down to diesel doctors dyno day and put my cabby with its new setup on the rollers. I was the only IDI to dyno today, alot of nice tdi's and even a 09 2.0 tdi ! so here is a video of one run and my dyno sheet.






I put down 133 hp and over 200 flbs of torque   Im pretty happy with that for now .

[hamradio]

Very impressive!  I'm envious.   


That thing must pull like crazy..bust up any 020's yet?

[giulianot]

 time for some updates. Last fall before putting the car away for the season I did a compression test and leakdown test. I found that cylinder 1&2 had low compression and were leaking at the intake valves, so i tore the head off again and sent it out for new valves and seals.

and the head comes off again 



I start to assemble refurbished head



I installed all new valve lifters , I used lucas as assemble lube



A shot of the bottom of the cam and the  head with the new valves and new precups pressed in



 a look at how bad my old precups were burned out from over fueling and high egts



Next I installed the cam and torqued down the caps



 glowplugs were next



then injector heat shields and injectors torqued to 51 ft/lbs







Exhaust manifold studs installed



Intake manifold torqued to 15 ft/lbs



Exhaust manifold spacers installed



Finally the exhaust manifold gets torqued to 15 ftlbs



the kkk 24/26 gets bolted to the exhaust manifold and torqued to 50 ft/lbs



Now the head the ready for install so I cleaned the block and put in a new 2 hole head gasket and placed the head on the block. I reinstalled the arp head studs and applied the arp approved lube and torqued the head to 75 ft/lbs.
I connected all the hoses and put some coolant in it started write up!

[burn_your_money]

Looking good buddy. Hopefully we get some more go out of it on Friday

[rabbitman]

I bet a better intake manifold would get you more power/lower EGT's.

[NintendoKD]

That is the PD mani isn't it, wasn't aware that there was one better than that.  Nice build.

[theman53]

No it is the regular one with no blow off valve.
PD is better.
Performance had one even better.
I got the "best"...I just need to fit it.

[rabbitman]

Where'd you find the new precups?

[NintendoKD]

 :oYEAH! what he said!!!  where did you get thems cups???

[giulianot]

I really dont know were my head rebuilder got the new precups from, maybe a dealer item only

[NintendoKD]

just who is your rebuilder, or will you tell?

[giulianot]

His name is Jim . He was recommended by a friend of mine, and I was happy with his work. he is located in hamilton, ontario, canada and his phone number is (905) 544-8514

[Dr. Diesel]

I just posted a vid of this car in the General section.

[giulianot]

I dynoed the cabby on sunday and here are the results

with a dr. diesel high lift cam and a giles pump and k26@24psi egts 1600-1800

[Dr. Diesel]

Your car did really well, G! Far more entertaining to watch than any other vehicle that rode the roller.
Copies of this camshaft will be available soon.

And, here's a quick vid of Giuliano's cabby on the dyno.

http://smg.photobucket.com/albums/v225/vwpics/?action=view&current=MOV00274.flv