1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)

[8v-of-fury]

Went down to my buddies for the weekend and I traded his dad a day of back breaking labour on their chicken farm (x2 350ft X 50ft barns which are two levels..) for this !!!!! NICE Full stainless, even the flex, and yes that is a cherry bomb.. also stainless. 2.25" mandrel bent and fully welded. 




And of course, shes running great and sounding even better.. think Peterbuilt style haha. so I had to tear back in to it again haha!

Got EGT, Boost, PD150 intake, .216's, and hopefully an AWIC if I can swing the cash .

[RabbitJockey]

So u got a an exhaust for spending time with a bunch of chicks?  Doesn't sound like a baddeal

[ORCoaster]

More likely the feathers and poop they leave behind. 

[8v-of-fury]

Well originally I was just gonna pay him $200 total for materials and his time.. but instead I traded my body. haha. I worked with no chicks, just his crazy farmer cousins. Super farmer family.. His dad has 14 other siblings.. He has like 49 first cousins!!!!!

It is a fully beast exhaust though, he even polished the part that sticks out from under the car.. so it looks like a tip.. but wont rust . I will most certainly have to update the exhaust note thread when I get it all back together. I've got the engine bay torn right back down now and am doing a WHOLE TON of reorganizing. I wanna put the battery in the trunk and then run a fuse block up in the bay to power all of what I power directly from the battery currently.

Here is something I wanted to run by you guys as I am curious as to why it is this way.. Me and my brother both have mk1's (you all probably know this anyway hah), they are both powered by 1.9's. Mine being the M-TDI and his being an AAZ. I have a turned down 11mm pump and stock injectors, and he has a maxed out 9mm and stock injectors (albeit the IDI injectors are plenty oversize). Both have new bearings, and no drag on the brakes. We have similar transmissions so we cruise within 50 RPMS of each other as well. I know I have a 180 stat, and I am sure his is similar.. They both also have non inter-cooled k03's

Now what I want to know is why my cruising temps are 180-190 and his are 165-175, I will pull a hill and my temps (on a hot sunny day) could easily rise to 205.. his barely touches 180. We even have the same short non-ac mk1 radiators.

I thought the DI was supposed to use less fuel for a given RPM over their IDI 1.9 counterpart?? Thus less heat from combustion.. not to mention less actually lost in to the cooling system via thermal transfer. SO what the hell is going on here lol.

I have a theory, the injectors seem like they are RETARDED dirty as it s

[410]

My guess is that your overall timing at your cruising speed is too advanced.  Had a similar issue with my toyota pickup with a mtdi.  If the timing was right, the rad fan would never come on.  If I advanced it too much it would run hot on the hills and the rad fan would come on regularly.

[RabbitJockey]

they are 2 different ko3s from i know too.  but still i'd think its something timing or fuel related before anything else. and maybe his thermostat is stuck open some too.

[libbydiesel]

Are you running the same max boost?

[RabbitJockey]

did they serve you lunch?

[libbydiesel]

The AAZ and 1Z/AHU K03 turbos are functionally the same.  The center sections and compressor scrolls are identical.  The turbine housing is oriented differently with a different flange but I believe the AR is still the same.  The wategates are different. 

[8v-of-fury]

Are you running the same max boost?

No, but I was not considering WOT or high boost pulls, merely at cruising speed. The two engines, albeit different injection are nearly identical so I assumed mine would cruise cooler being that it is DI. How do the waste-gates differ? I want to assume the AHU ones are maybe larger or more efficient at diverting the airflow?

maybe his thermostat is stuck open some too.

His gets up to temps super quick, so I do not figure a stuck open thermostat.

did they serve you lunch?

Haha, not that kinda lunch.. but yes I was provided lodging, food and too much beer .

[libbydiesel]

The AAZ wastegate pushes closed and pulls open on boost.  The TDI one pulls closed and pushes open on boost.  I prefer the TDI one as boost is on the sealed diaphragm side.  The AAZ version has boost on the shaft side with a seal around the shaft and so it seems they all leak blowby oil. 

You should take both cars to the top of a long hill and coast down.  See which one gets going faster and coasts further.    Do you have similar tires and tire pressure?  Wheel bearing components and CV joints are similarly fresh?  What I'm getting at is that your mTDI may have greater rolling resistance and the added load could easily account for the added temps.

All said and done tho, I think you have a timing or injector issue. 

[8v-of-fury]

I for sure know that I have dirty injectors in there currently, I get a good "retarded timing" style smoke with any amount of advance especially when cold.

I like your idea of the hill, a good test. If anything mine SHOULD have less resistance. I have brand new bearings all around, no brake drag, two new axles and a fresh alignment and also run a 45psi tire pressure. His is out of alignment, has however old axles (probably stock), ballooner tires and more conservative 32psi. I don't know, I too think it is fueling.. gotta be.

I noticed with the DI the injection sound did not really change with any amount of timing advancement.. Like I even went a tooth further on the pulley and it didn't change anything.

[8v-of-fury]

So yeah, get it running good.. TEAR BACK IN TO IT! haha



All four look like this one, have not had any more build up or anything since I cleaned it out a few years back. Drove around for a while with the EGR still hooked up. Could use another slight cleaning it would seem haha.



Ohh they are dirty.. and I can get number three out.. will not budge! I was gonna hit the head with a torch.. but its a blizzard here..




Also check this siht out... I opened the pump today to do a little modification and this is what I found. The clip was floating around the pump, and the missing piece was no where to be found.. ? It left a good gouge in the bottom of the case, and looks like it got logged for a bit because it sheared the rubbers in the gear that spins the governor assembly! WHOA.






Here is one of the reasons I pulled the pump apart for, I have a good wear mark in the pumps main shaft.. That I was either thinking of getting welded and filed down, or just cutting the seal back to ride a different part of the shaft.

[8v-of-fury]

Also, I will be needing new coolant lines for two reasons.. Stock oil cooler delete and because they were damn near rotten through! I have no idea how they haven't blown yet. Wow, they were sooo soft and crap. I will be needing a different bypass hose as well as a different water pump to the metal hard line to delete the stock oil cooler from the cooling system.

I was thinking I could easily use a 1.8's hoses and probably lengthen the bypass hose to account for the taller block.. but the 1.8's upper flange goes in to the side where as the AHU's is on the bottom ish.. So get stock AHU stuff and cap the un needed ports??

Anyone got good cheap sources for me?

[RabbitJockey]

go to your local parts store and ask if you can go in the back and check out their hose.   

they'll usually let u look through their inventory and then maybe you can find one that will work.  also maybe non turbo 1.6 stuff will work?