~My 91 GLI to 1.6TD conversion build up~

[53 willys]

haha thanks guys...much better response then I got on vortex...lol




got some more goodies today :twisted:

210mm race clutch with small 24 splines for the ASF trans.

clutch, ARP head studs and dual A-pillar pod


 G40 polo valve cover


lightened IM shaft


cleaned up ASF trans next to the GLI 2Y
I still need to swap the flanges....just waiting for my seals from Myke.


DIY port and polished head


the machine shop peened the cracks between the valves


also got my Benz tiped injectors!



almost ready to put this beast together!!


 :twisted:
i was gonna run a metal head gasket...but I am just to scared of the mods to make it work....if I blow the stock fiber then maybe I will try the MLS gasket.

[zukgod1]

I'm jealous of the clutch for sure!!!

[53 willys]

for anybody who cares.....here is some small tech..
the transfer pump in the fuel tank of the gas VW's output is 6-7psi...I am gonna run it as a lift pump for my diesel conversion.
this is a perfect PSI for a lift pump

[Ziptar]

mmmm... Nice parts.  

BTW: I think that might be a G40 valve cover, the G60 has the oil fill and PCV holes reverse of yours, at least mine does.

[jtanguay]

for anybody who cares.....here is some small tech..
the transfer pump in the fuel tank of the gas VW's output is 6-7psi...I am gonna run it as a lift pump for my diesel conversion.
this is a perfect PSI for a lift pump

i thought that the pressure for the mechanical injection was 35 psi or so?

[53 willys]

mmmm... Nice parts.  

BTW: I think that might be a G40 valve cover, the G60 has the oil fill and PCV holes reverse of yours, at least mine does.

your probably right?? the guy I bought it from said it was a G60...but all the g60 ones I have seen are slightly different then mine. there was no pic in the ad so I never saw it till it showed up :oops:

[53 willys]

for anybody who cares.....here is some small tech..
the transfer pump in the fuel tank of the gas VW's output is 6-7psi...I am gonna run it as a lift pump for my diesel conversion.
this is a perfect PSI for a lift pump

i thought that the pressure for the mechanical injection was 35 psi or so?

I put the sending unit in a bucket of diesel last night and put a gauge on the output line of the pump and my gauge read 6-7psi....the high pressure pump that the transfer pump feeds is like 78psi

[53 willys]

mmmm... Nice parts.  

BTW: I think that might be a G40 valve cover, the G60 has the oil fill and PCV holes reverse of yours, at least mine does.

your right I just did some googling and it's a "polo G40 valve cover"
I guess that will work???

I even found one installed on a diesel!....http://forum.myspace.com/index.cfm?fuseaction=messageboard.viewThread&entryID=54226001&groupID=100000193&adTopicID=2&Mytoken=7854EEBD-5DEE-4859-870F9CB092A7795A2139473

[lildevil]

haha mint man, cant wait to see this done, come back to the vortex when its done...im sure they will be like "ohh thats sooo coool, howd yuou do itt" bunch of nut swingers lol

[gigaz2]

nop, not a G40 valve cover for sure, G40 has a pipe going through it.

also, the G40 engine isn't based on the 827 design, so the valve cover shouldn't be compatible.

it's very nice anyway, me wants

[Turbinepowered]

for anybody who cares.....here is some small tech..
the transfer pump in the fuel tank of the gas VW's output is 6-7psi...I am gonna run it as a lift pump for my diesel conversion.
this is a perfect PSI for a lift pump

i thought that the pressure for the mechanical injection was 35 psi or so?

CIS is approximately 70-75psi injection pressure, but has two pumps to attain that. The in-tank lift pump is very low pressure, and it feeds the primary, external high pressure pump.

[53 willys]

so is that a G60 or G40 cover??? I'm confused??

[Ziptar]

I thought it was a G40 but I guess not, maybe two styles of G60??

It'll work, just have to shorten / replace the PCV hose.

Not sure if you bought these yet but....

Make sure you use the rubber valve cover gasket with it  and have the plastic oil splash shield under it. If you do that, you'll have to learn to live without the usual VW diesel valve cover leaks.  

Rubber valve cover upgrade kit (comes with studs) is 026 198 025 C German Auto Parts.
Splash shield Part # is 026 103 547 and is available for $5-$7

[53 willys]

I thought it was a G40 but I guess not, maybe two styles of G60??

It'll work, just have to shorten / replace the PCV hose.

Not sure if you bought these yet but....

Make sure you use the rubber valve cover gasket with it  and have the plastic oil splash shield under it. If you do that, you'll have to learn to live without the usual VW diesel valve cover leaks.  

Rubber valve cover upgrade kit (comes with studs) is 026 198 025 C German Auto Parts.
Splash shield Part # is 026 103 547 and is available for $5-$7

thanks for the tips...yeah I already picked up the shield and the rubber gasket and studs....lucky for me Zukgod1 is in the next city over and he has been helping me with all the parts and things I need too.

[53 willys]

so my K24/26 hybrid is a water cooler version....

I know some dont like this set-up but I got the turbo cheap and I will run it till I can afford a ball bearing turbo....anyway I am wondering how the water lines should be plumbed?? does anybody have pics of the water line plumbing on a VW diesel?? anything I should know about plumbing it??
Zukgod1 was telling me you can run it without the coolant lines....But i dont have a problem plumbing the lines and if it helps cool the turbo it should help it last longer so I would like to run them unless there is some other issue I am not aware of???
thanks in advance