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Author Topic: Golf II GTD with 1.9 AAZ engine --- EVO II  (Read 150617 times)

Reply #285April 25, 2016, 03:51:50 pm

RabbitJockey

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Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« Reply #285 on: April 25, 2016, 03:51:50 pm »
complete swaps or swap cars are always smart to use.
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #286April 25, 2016, 04:29:05 pm

vanbcguy

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Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« Reply #286 on: April 25, 2016, 04:29:05 pm »
AFN will be a great engine for you - tons of potential there!
Bryn

1994 Jetta - AHU M-TDI - Jezebel Jetta
2004 Jetta Wagon - 1.8T - Blitzen

Reply #287December 08, 2016, 05:59:40 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« Reply #287 on: December 08, 2016, 05:59:40 pm »
Hi,

the guy did not call me back and i do not get him back to the phone in April, so nothing happend until now. But today i buy an Golf MkII with an AFN engine, and bring it to my garage. I will use the engine the electronic from the new golf for my red golf, so my TD will get an TDI.

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

Reply #288December 09, 2016, 02:50:02 pm

RabbitJockey

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Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« Reply #288 on: December 09, 2016, 02:50:02 pm »
great, is an afn an 058 block?  will you be experimenting with the same turbos still?
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #289December 09, 2016, 05:39:55 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« Reply #289 on: December 09, 2016, 05:39:55 pm »
Hi,

i do not know the block code, but it should be the same as 1Z / AHU and the earlier type 1.9 TDI's. I think the AFN was the first with VTG turbo and it have a more step (4,1mm) camplete  in the injecton pump. The stock power is 110hp.

I will go for VTG turbo, but bigger than stock, or to say biggest i find. My daily driver is a BMW E34 525TDS since a couple of years and i am running a GT2556V (E39 530D) with boost can an electronic boost controler. The BMW has an autobox and do not see to high rpm's quite often, the boost control with the electronic boost controller works quite well, i only have slightly overboost by going full load after no load at higher rpm's. Which turbo i use is still open, i could end up with a GT1749V / GT2052V hybrit, an GT2056 or even an GT2556V, as i have experience with the turbo and they are cheap to buy. I also think about the manifold, if i should use the stock manifold or use the one, i have used on the AAZ engine.

The benfit of VTG are to high to go forward with wastegate turbo's for me. With wastegate's you have either big lag or big power restriction and high egt's or you need a perfect turbo and are willing to go 2,0 bar or more at high rpm's. The other benfit of VTG turbos is the more easy package, because you do not need external wastegates.

Regarding my swap, yesterday everthing seems to be clear and i was willing to take over the whole package including the hole electronics, but now i think again if mtdi could be more fitting to me. I like the idea of being in full control for fuel with a screwdriver and 13mm spanner.

As summary the hole engine build is not fixed in my head. What is for sure is that i will rebuild the head, use a regrinded camshaft, go back to organic sachs performance coupling and will use a bigger VTG turbo. The pump will 11 or 12 mm plunger with AFN camplate and i have no idea what nozzles to use. I like to have to the pump, turbo and nozzle be ready for 200hp+ and will be happy with everthing above 180-190 hp.


Best Regards
Alleslowbuged   

   
« Last Edit: December 09, 2016, 05:49:51 pm by Alleslowbuged »
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #290December 14, 2016, 06:00:28 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« Reply #290 on: December 14, 2016, 06:00:28 pm »
Hi,

i am get some progress in my overall plan, actual it looks like 200hp with matching hardware to make it reliable.

fixed (nearly) shedule:

- ported head, pherhaps with bigger valves,
- regrinded camshaft
- ARP head bolts
- GTB2056VK Turbo
- 0.260er Nozzles
- d=11 (pherhaps d=12) plunger for the injection pump
- custom intake - Volvo 5-cylinder

open shedule:

- Exhaust manifold (tubular type - facing down, or the same as before - facing up)
- intercoller (stock GTD as before, or front mounted)
- IP elektronic / mechanic oder mechanic with electronic timing control

I know that using the full electronic package would be the best solution, but the idea of an 200hp TDI in an MKII Golf, with an mechanical pump, upfacing turbo and stock GTD intercooler, which looks like the stock 1.6TD at the first glance, is very appealing to me.

I do not have any experience with M-TDI's, so i do not have any experience if it is possible to handle that properly. I would like to use a mechanical pump with electronic timing control, as in the latest AAZ's, because i think that is the weakest point of the mechnical package. I have had the thougth of swapping the hole package and than swap the pump to an mechanical with elec. timing control and only conect the PWM valve to the harness. But i do not know if the ecu will work, when the pump head is not conected and i would need e-throttle and cable at the same time. So only woolgathering.

Best Regards
Alleslowbuged

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

Reply #291December 15, 2016, 11:03:35 am

RabbitJockey

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Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« Reply #291 on: December 15, 2016, 11:03:35 am »
058 would be ahu/1z style 06a is later internal water pump style like an alh.

i think keeping the gtd intercooler would be fine, you have shown with your aaz that it did not seem to limit power

you may want to have the exhaust manifold facing up because of the rear engine mount

your pump is easy in either direction, the land rover pumps have been show be great pumps which are easily adapted to work on a vw engine.  you already have experiencing with modding the pump.  but this route will make controlling the vnt turbo challenging, or you could run your old turbo and manifolds, it all bolts up, no need to spend more money.

electronic pump is also very easy if you swap in a passat pedal assembly then the drive by wire hardware is all in place, and it makes controlling a gtb2056vk easy.
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #292December 23, 2016, 06:50:15 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« Reply #292 on: December 23, 2016, 06:50:15 pm »
Hi,

i have increased my power goal to 230hp and have ordered a ported head with 37/33 oversized valved and a performace cam with 9.5mm lift today. I would have liked to use a 10mm cam, but than i must have pulled the pistons and machine the valve grooves.

The turbo has also changed to a GTB2060VKLR with ball bearings, vacuum control and a T3 flange, which will be installed on my kinetic manifold, so general arrangement will be as with the AAZ.

Due to the increased power goal i will also using bigger nozzles, but i struggle to decide if either 0.28 oder 0.32 would be better. The pump will be with electronic control and i will use the 12mm plunger from my mechanical pump. I was told to use the camplate from an ALH pump (DE134), did anybody here knows what stroke that has and if there is an different to the AFN camplate with 4,1 mm stroke?

So the plan is ready and i need parts and time to install them. I have also started to strip the AAZ, but the cylinderhead is still in place so i do not know how the cylinder and pistions looks, but i will make pictures if the head is down.
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #293December 30, 2016, 06:10:08 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« Reply #293 on: December 30, 2016, 06:10:08 pm »
Hi,

here are some pics as update and keep the thread a bit more alive, as only a lot of text.

This is "my" Golf last week:



and this is from wednesday:

head pulled:


search for the failure (tip: keep an eye on all pistons)


some extra ventilation for the oil pan


The head looks and feels fully ok


if someone want a ported AAZ head with regrinded camshaft, valves seats mashined to run with stock bottom end and ready for 190hp, here it is for sale:
 


and here are some pics of the donor car, it is a little bit a shame to strip it back:

Golf MKII
- plus axles with 5x100 and 288er brakes
- e-gas and hydraulic clutch actuator
- e-windows
- central locking
- full converted wiring loom to fit AFN engine with fully working seat ibiza tacho with MFA
- 02a gearbox
- good interior
- power steering
- etc..

first day:






wednesday:




I am realy happy that i could fix the "no power" issue today, because now i know i can swap 1:1 all the parts and the engine will run in my golf also.

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

Reply #294December 31, 2016, 02:14:59 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« Reply #294 on: December 31, 2016, 02:14:59 pm »
Hi,

i have ordered an AFN pump with 12 mm head and DE110 camplate (3,1 mm stroke) today, so that is fixed also.

Best Regards and a nice to 2017 to everybody
Alleslowbuged
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #295January 04, 2017, 03:16:48 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« Reply #295 on: January 04, 2017, 03:16:48 pm »
Hi,

i came to a conclusion regarding the nozzle size. As written i was unsure if 0.260 or 0.280 would be best and came up with the following thoughts:

The Afn has 110hp, a 10mm pumphead and 0.205 nozzles as stock and i would say that there is at least 20% margin left in regard of fuel / power without sacrificing injection time duration to much. So i can say, a 10mm pump head and 0,205 nozzles are good for min. 132 hp with suitable injection time duration and good atomisation.

When i go from 10mm head to 12mm head this means an increase of 44% in regard of flow per stroke (assuming that the volumentric effeciency is the same , even if it is not the same at high rpms). So by increasing nozzle size also by 44% should bring similiar injection time duration, injection pressures and atomisation @ 44% higher fuel rate and therefor 44% more engine power. This would mean 190hp and 0.246 nozzles.

So to go over 190hp means either bigger pump head than 12mm, or increase injetion time durartion to get more flow, or sacrificing atomisation by using bigger nozzles. As i want to rev to a certain level, bigger pump head is no option.

So its injection time vs. atomisation to find the best compromise. The nearest available nozzle options are 0.260 and 0.280, which means 14% vs. 30% higher flow rates above the calculated 0.246. In engine power this would mean 216 hp vs. 246 hp with a similar injection time duration as a stock AFN with a 20% remap, but worsen atomisation.

I think based on this thoughs both nozzles sizes would be still an option, but it is clear that the 0.260 nozzle will not have much margin left @ 230hp in terms of suitable injection duration times. Adding the fact that the 12mm head will loose some of its volumetric efficiency at higher rpms, the margin will be even smaller, even if i have no doubt that 230hp will be possible with 12mm head and 0.260 nozzles.

My shedule is to use 0.280 gibonta nozzles, mainly because i am concerned about the cambelt and the high pressure plunger. If i would use a 12mm head with 0.246 nozzle @ 190hp, this would mean approximate 44% more torque for the pump plunger and the cam belt to handle. For the 0.260 and 0.280 nozzles @ 230 hp i am not so sure about the percentage increase in torque, because both will end up with lower injection pressures, but it is for sure that the 0.280 nozzles will stress the pump and the cam belt less than the 0.260 nozzles.

Just to make clear, i know that all this is only a simple a linear approach and the reality is bit more complex, but as we speaking about a fluid as medium i think the approach as above, should be suitable for getting some rough numbers to orientate. To realy see the mentioned power figures there should be enough air to burn all the fuel injected as well, but this is another topic.

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

Reply #296January 05, 2017, 08:49:51 am

RabbitJockey

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Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« Reply #296 on: January 05, 2017, 08:49:51 am »
it does seem like a waste of energy to swap engines... maybe just enjoy both cars some how?
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #297January 05, 2017, 08:50:30 am

RabbitJockey

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Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« Reply #297 on: January 05, 2017, 08:50:30 am »
also what happened that allowed the pistons to hit the valves?
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #298January 05, 2017, 04:10:45 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« Reply #298 on: January 05, 2017, 04:10:45 pm »
Hi,

@RabbitJockey

I agree, that it would make more sence to keep the black golf together and just make it better with parts from "my" (red) Golf. But it would have make even more sence to buy an MKIV with an stock AHF / ASV engine and just bolt some parts on it. If you have make a Golf MKII ready to cope with 200hp, the weight advantage shrinks to just a fraction.

To be honest, i mainly keep my golf, because i have some kind of relationship to all my cars and after having a lot of ups and downs (more ups) over a couple of years, it seems just not fair to jump in next best car available and forget the old one. It is also not good for the KARMA -- a friend has swaped her motorcycle to a newer one of the same model, just because it was newer and than has only has problems the hole year. The old one was bougth as new by her and never missed a beat over serveral years.

The black golf is worse than the pictures suggest, but not bad at all. At least it would also need some work to finalize and there are also some pros for my golf, it has PU bushings all around, widen weel arches to fit et13 rims and look nearly oem, brand new rear disks, new front subframe, front splitter, nicer interior and at least it is red (i like red more than black on cars).

Best Regards
Alleslowbuged

P.S. I try to convince my friend, who will help me with the engine swap, that he wants the black golf and i suggest that he will organize a new AAZ block and we will put a new AAZ (~160-170hp) in the black one.
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #299January 05, 2017, 04:59:54 pm

Alleslowbuged

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Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« Reply #299 on: January 05, 2017, 04:59:54 pm »
Hi,

here are some pics of the intake:







looks good


not so good


comparison with Pd150 intake










I would love to increase the volume of the plenum and make it a dual plenum, but i can not weld alu und all my attemps to built a "custom" intake did not went well - pherhaps somtime in the future
 
Best Regards
Alleslowbuged
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD