Author Topic: Golf II GTD with 1.9 AAZ engine --- EVO II  (Read 150624 times)

Reply #45August 23, 2011, 05:44:03 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
« Reply #45 on: August 23, 2011, 05:44:03 pm »
Hi,

i did some fine tuning on the BorgWarner MatchBot and slowly get what a wonderful tool they gave us unknowing people.
Here is what i put in and what came out for my S2A (don't be astonished by the plots for the EFR-6255):

http://www.turbodriven.com///performanceturbos/matchbot/index.html#version=1.2&displacement=1.9&CID=115.938&altitude=500&baro=14.456&aat=75&turboconfig=1&compressor=62k80&pt1_rpm=1500&pt1_ve=88&pt1_boost=4.4&pt1_ie=85&pt1_filres=0.08&pt1_ipd=0.2&pt1_mbp=0.5&pt1_ce=58&pt1_te=70&pt1_egt=1550&pt1_ter=1.2&pt1_pw=3.74&pt1_bsfc=0.34&pt1_afr=15&pt1_wts=300&pt1_wd=83&pt1_wd2=74&pt1_wrsin=69033&pt2_rpm=2200&pt2_ve=88&pt2_boost=18&pt2_ie=85&pt2_filres=0.1&pt2_ipd=0.8&pt2_mbp=1&pt2_ce=58&pt2_te=73&pt2_egt=1600&pt2_ter=1.78&pt2_pw=0.19&pt2_bsfc=0.35&pt2_afr=15&pt2_wts=320&pt2_wd=83&pt2_wd2=74&pt2_wrsin=73635&pt3_rpm=3200&pt3_ve=80&pt3_boost=30&pt3_ie=85&pt3_filres=0.12&pt3_ipd=0.9&pt3_mbp=1.3&pt3_ce=58&pt3_te=72&pt3_egt=1650&pt3_ter=2.44&pt3_pw=4.55&pt3_bsfc=0.37&pt3_afr=15&pt3_wts=340&pt3_wd=83&pt3_wd2=74&pt3_wrsin=78238&pt4_rpm=4000&pt4_ve=75&pt4_boost=30&pt4_ie=85&pt4_filres=0.15&pt4_ipd=2&pt4_mbp=1.5&pt4_ce=60&pt4_te=71&pt4_egt=1650&pt4_ter=2.63&pt4_pw=10.62&pt4_bsfc=0.42&pt4_afr=15&pt4_wts=368&pt4_wd=83&pt4_wd2=74&pt4_wrsin=84681&pt5_rpm=5000&pt5_ve=70&pt5_boost=30&pt5_ie=82&pt5_filres=0.18&pt5_ipd=2.5&pt5_mbp=1.8&pt5_ce=64&pt5_te=70&pt5_egt=1650&pt5_ter=2.74&pt5_pw=16.73&pt5_bsfc=0.43&pt5_afr=16&pt5_wts=400&pt5_wd=83&pt5_wd2=74&pt5_wrsin=92044&pt6_rpm=6000&pt6_ve=65&pt6_boost=30&pt6_ie=80&pt6_filres=0.2&pt6_ipd=3&pt6_mbp=2&pt6_ce=65&pt6_te=70&pt6_egt=1650&pt6_ter=2.85&pt6_pw=19.27&pt6_bsfc=0.44&pt6_afr=18&pt6_wts=400&pt6_wd=83&pt6_wd2=74&pt6_wrsin=92044&


I have also tried to measure main dimension and came out with that results:

   Compressor Wheel:  Ø39 mm / Ø61 mm      (Inducer / Exducer)
   Compressor Casing: 0.54 a/r

   Turbine Wheel:  Øxx mm / Ø54 mm      (Inducer / Exducer)
   Turbine Casing: 1.00 a/r

I still do not know if this is a S2A-61 or S2A-69, values in MatchBot deals with S2A-61 which should result in quick spool
and full boost of 2 bar around 3000 rpm. Exhaust backpressure will follow boost but will not overcome boostpressure up
max. rpm. I would like to have a bit bigger turbine casing to surely prevents surge, wich could be a issue.

Best Regards
Alleslowbuged   


 
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #46October 04, 2011, 02:53:20 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
« Reply #46 on: October 04, 2011, 02:53:20 pm »
Hi,

it takes me 4 full days (nearly 8 hours per day), but the engine run yesterday at around 19:00 again.

in sequence:

First i have change the original engine bearing (behind the engine) with a special built one, which use a control arm bearing from a Audi A8.
Because the inner diameter was a bit larger than the original one, i make a bush, even when the force will be tranferred due to friction and not due to the bolt.
Anyway, here are the pictures which shows both bearings, the new one should be much stiffer:






As next step, i have modified the ventilation plate, to fit with the new Spal fan:




It took me a long time to fit the flange adapter and the wastegate flanges, by the way the exhaust manifold gets a hole for EGT measurement:




Here how all together should look:





After i cleaned the engine block, i have also cleaned the piston surface and have to notice, that there was some contact between the piston and the valve with the old arrangement.





Than i have measured the gap between the old headgasket and the pistons (1,0 mm) and also the distance between the valve and the cylinderhead (spilt surface) (IV 2,4 mm; EV 2,1 mm) to calculate the distance between the valves and the pistons in OT (TC?) (IV 3,4 mm; EV 3,1 mm). I have also measured the max. lift of the valves due to the springs or the spring caps with 11 mm, which is not really much by a valve lift of 9,9 mm.

After the cylinderhead was put in place again, it was high noon, will the turbo fit behind (under) the fire wall?

first check (after allready change the way of some cables and dismount the heat protection):



Seems as could be done, so i bent the heat shield and mount it with two new distance spacer:



and HERE IT IS:



quite a tight fitting with the compressor housing:




The next problem to solve was the oil pipes:

Step one


Step two


Step three


making the last gasket for cooling water connector:





And put it all together an start the engine:







Unfortunately i missed to make a picture from below. Up to now the only problem which must still be solved is
the downpipe with the conection for the wastegate pipe. to be honest i don't have just a idea how to start
that, but comes time, comes solutions.

Best Regards
Alleslowbuged

« Last Edit: October 04, 2011, 02:56:52 pm by Alleslowbuged »
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #47October 05, 2011, 07:23:10 am

Alcaid

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Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
« Reply #47 on: October 05, 2011, 07:23:10 am »
How much clearance do you have between compressor housing and firewall? Engine will not stand completely still unless you changed the engine mounts to something solid...
'03 VW Golf PD130 4Motion Highline
'10 VW Passat 1.6TDI Highline
'83 VW Jetta 1.6TD, 11mm pump, H-beam rods, girdle, fully reworked AAZ head +++ Going Compound ;)

Reply #48October 05, 2011, 02:48:49 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
« Reply #48 on: October 05, 2011, 02:48:49 pm »
Hi,

the clearence is only a few mm to the heat shield and heat shield to firewall again ~ 2 mm.
It is clear that the engine will move a bit, i hope that the new "special" engine bearing will prevent to much movement, but
in fact i have to wait until the first drive, bevore i will know if it is enough clearence or not. At least i can bent the firewall
in that area a bit, but from my feeling it will be ok.

Best Regards
Alleslowbuged
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #49October 05, 2011, 02:58:39 pm

Alcaid

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Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
« Reply #49 on: October 05, 2011, 02:58:39 pm »
That is not enough clearance! :o
'03 VW Golf PD130 4Motion Highline
'10 VW Passat 1.6TDI Highline
'83 VW Jetta 1.6TD, 11mm pump, H-beam rods, girdle, fully reworked AAZ head +++ Going Compound ;)

Reply #50October 05, 2011, 03:03:32 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
« Reply #50 on: October 05, 2011, 03:03:32 pm »
Hi,

did you see, that i have a special engine bearing?

Best Regards
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #51October 06, 2011, 08:34:51 am

Alcaid

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Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
« Reply #51 on: October 06, 2011, 08:34:51 am »
If the mount is so stiff that the engine won't move a couple of mm, I guess your car will shake apart! ;)
'03 VW Golf PD130 4Motion Highline
'10 VW Passat 1.6TDI Highline
'83 VW Jetta 1.6TD, 11mm pump, H-beam rods, girdle, fully reworked AAZ head +++ Going Compound ;)

Reply #52October 09, 2011, 05:06:38 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
« Reply #52 on: October 09, 2011, 05:06:38 pm »
Hi,

it seems to be realy a bit mor "shaky" as i like.

I have start to fabricate the downpipe this weekend, actualy i am finished the vertical part and
have the downpipe face the catalysator. I will add a flexpipe and make an aditionally support in
the near of the catalysator, then i have Ø 63,5 mm straight ahaead all the way down.

What is still open to make is the wasteagte pipe.

Here some pictures:













Best Regards
Alleslowbuged
 
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #53October 16, 2011, 04:35:28 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- party fog mashine
« Reply #53 on: October 16, 2011, 04:35:28 pm »
Hi,

it is as it seems to be allways.

I have meke my first few km wih the new setup, and besides a bit oil leak from the drain pipe of the turbo, it seems to ok.
Engine has good start, stable idle and feels prettry good in NA mode (no boost 1000 rpm - 2000 rpm).

BUT, it smokes white like hell, especially at idle when the engine is warm. Up to now i did not have make any measurements
or checks, so could be a few things. But my assumption is that there i a leak between the cooling system and a exhaust port
in the cylinder head. As i wrote, i can the start the engine normal (cold and warm) and it rand also normal but smokes like hell.
So i assume that there is no water in the cylinder. An additionally hint is that the downpipe flange seems to be a bit wet, last
weekend after i have start the engine for a few minutes.

Anyway here are the last pics, which shows all together before the ride out:











Besides, the stiff engine bearing really transver all kind of vibration into the cabin.

Best Reagrds
Alleslowbuged
       
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #54October 20, 2011, 03:58:00 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- party fog mashine
« Reply #54 on: October 20, 2011, 03:58:00 pm »
Hi,

i have make a few more km with the AAZ Golf, but it still has make a lot of white smoke.
I have also notice that the adapterflange is allready cracked after long 8 km with less than
3 psi boost pressure and not more than 2800 rpm.

Afterwards i have dismount the turbo and the exhaust manifold and have notice that i really
have a collant leackage in the exhaust port of the first cylinder.

f*** O*f



Best Regards
Alleslowbuged
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #55October 26, 2011, 01:20:31 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- crack picture
« Reply #55 on: October 26, 2011, 01:20:31 pm »
Hi,

i have spoken with a engine rebuilder on monday, which claims to have experience with
welding cylinder heads, but also says that this is a difficult thing. I have send him pictures,
but he did not call me back up to today. I will try to find a second opinion, if someone here
knows a shop with big experience with my issue, i would really apreciate if he sends me a PM
with the contact details.

Here are the pictures:







Best Regards
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #56November 03, 2011, 08:39:52 pm

ibizz

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Re: Golf II GTD with 1.9 AAZ engine --- crack picture
« Reply #56 on: November 03, 2011, 08:39:52 pm »
thats bad

too mutch porting ?

may be a new used head is more economical than a repair

i hope it all be fixed soon


Reply #57November 04, 2011, 12:03:44 am

theman53

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Re: Golf II GTD with 1.9 AAZ engine --- crack picture
« Reply #57 on: November 04, 2011, 12:03:44 am »
You are on the right path. That is exactly what my guy says happens when porting right, SOMETIMES. The water jacket is right there and some castings aren't all that great and you get a little bleed through. Shouldn't be to hard for an experienced guy to TIG. I wouldn't scrap it that is for sure.

Reply #58November 05, 2011, 09:57:39 am

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- crack picture
« Reply #58 on: November 05, 2011, 09:57:39 am »
Hi,

thank for your oppinion. I also realy don't wand to scrap the head, not only because the porting (i thnik the guy who make the proting, will reply the porting on a new head for almost free of charge, because this crack happend), but as i wrote the head has a special valve grinding, which makes more room for valve hub.

I still do not have a statement of a shop, who says "yes we have experience which welding cylinder heads and we can do it".

Best Regards
Alleslowbuged
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #59November 08, 2011, 03:33:00 am

Toby

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Re: Golf II GTD with 1.9 AAZ engine --- crack picture
« Reply #59 on: November 08, 2011, 03:33:00 am »
I would not try to weld up the area of the water leak. It will likely just fall through when the puddle forms making a much bigger hole. All of this cam be fixed, of course, but only by heating the head to the point where it warps and seats and guides may drop out. BTDT

I would try some of the low temp (400*F) aluminum solder to seal up the leak. You can solder aluminum radiators with it. Its PFM (Pure Fargin Magic) and cheap. If you can't find it over there I could mail you some.

 

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