Apparently I got a little carried away this weekend - page 1 - General - VWDiesel.net The IDI, TDI, and mTDI source.

• Apparently I got a little carried away this weekend by burn_your_money on 03 Jul, 2010 20:14
• So it all started 2 summers ago when I decided to cut the lines going to my power steering pump on my Golf. The tabs on the front of the block had broken off for the power steering pump mount so it was kind of swaying in the breeze. It was impossible to keep the belt tensioned and as a result I was afraid that my waterpump would not be spinning enough. What I should have done was hook the 2 lines together but I didn't.
  Fast forward to last fall, the steering now gets "locked" in position when I go near full lock. I have to yank very hard on the wheel to get it to straighten out.
  I picked up a manual rack from a friend and decided that I should get a beater car on the road while I swap the rack out. From what I have read these things either go smoothly or everything breaks and you are without a car for weeks. Well I get the beater on the road (my 89TD pos) and one thing leads to another and I still hadn't touched my Golf. Since I had swapped in the non turbo AAZ I've been playing around with different 1.6 NA intake manifolds trying to find one that gave good power and fuel economy. Then I stumbled across this little gem in Germany.
  
  I was buying a GTD intercooler setup off the same guy so I had him throw it in the same box to save on shipping costs. Unlike all the other NA intakes in North America this one requires a separate air box and unfortunately it has an EGR so it's full of crap. This is what the plenum looks like, gross eh?
  
  So this weekend was the weekend. I pulled the Golf into the shop on Friday morning (we were closed because of Canada Day) and started pulling stuff out. I've replaced one steering rack before and I did it by dropping the subframe. Since there were so many other things I wanted to do to my Golf I figured I would yank the engine out and do it that way. 3 hours later and the engine was out and the new rack was in. My only oversight was the fact that the boot that goes from the rack to the firewall is totally different between power steering and manual steering. I have a garbage bag ziptied in place for the time being. The stupid boot is NLA as far as I can find
  I took the time to pressure wash my engine bay while I had everything out. It was pretty messy from my "performance exhaust"
  
  It's about this time that I recalled that my engine used to have an EGR when it had a turbo on it. All my intake runners looked like this.
  
  Dr Diesel has been harassing me to make my NA "fast" ever since he and I did all that work measuring camshafts and whatnot. I've always regretted the carbon buildup in my head so I figured the engine's out, I have a performance cam to install, it would be wasted if I don't clean this crap out.
  I figured the best course of action would be to pull the head and give it a good, proper cleaning.
  
  
  You can probably see all that rust below the front coolant flange. I've overheated this poor engine more times then I care to recall so I was pretty worried about the head being warped. It's at the maximum allowable warpage so hopefully the headgasket seals. I'm undecided if I should use a fiber gasket instead of the metal one.
  I've also decided to replace that lovely green valve cover. I could never get it to stop leaking so I'm going to go with a G60 valve cover instead. Hopefully that will solve my oil problems.
  So while I was cleaning the head I figured hey I'm this far along, I may as well port this thing a bit. A quick phone call to Dr Diesel for some know-how and out comes the Dremel.
  I started with the exhaust ports. I've always read that they should be smaller then the exhaust manifold to create a step. I don't know if this is just a gasser thing or not but figured I would follow suit. I placed the exhaust gasket over the port and traced an outline of gasket opening leaving about 1mm all the way around it. Here you can see my scribe line
  
  This one just shows how much extra material there is.
  
  And this shows stage 1, porting it to match my scribe line
  
  Then I smoothed out what I had just removed to the stock runner diameter over about an inch into the runner. No pictures of this for some reason.
  Then I turned my attention to the intake ports. They were very good but there was a bit of room for improvement. Since I didn't have a bunch of soot to scribe a line into I used a permanent marker and colored the area around the port. Then I copied the intake gasket pattern onto the head using my scriber. This is the result
  
  You can see in that picture that there is very little material to remove. Again, I blended what I did into the runner over the course of an inch.
  Here is a picture of the final product after I sanded everything with a flap wheel.
  
  Now it was time to turn my focus to the valve area. Once again the intake was pretty good from the factory but the exhaust was crap. There is a huge hump all the way around the runner about 3/4 of an inch into the runner. Dr Diesel said it has to go so I did what I could.
  Anything that is shiny has been ported. All the runners were either black with soot or EGR crap when I started. Hopefully you can see what I did in these pictures.
  
  
  
  My head now flows this much better (that's a 13mm cam cap nut)
  
  I sure hope what Dr Diesel was telling me over the phone translated properly into my head
  
  Here is how I removed my valves
  
  And this is how I checked my valve guide wear
  
  
  Now to put it all back together and show some turbo people what's what
  
• #1 by 8v-of-fury on 03 Jul, 2010 20:49
• I dunno, do you still drive a sluggish 1.9 N/A? jks that is a lot of work you did there! I wish i too had a shop to work in.. Only got the damn driveway and the sunburn that subsequently follows.. lol
  
  Wanna port my 1.6 head? 
• #2 by Baron VonZeppelin on 04 Jul, 2010 09:48
• I could have done all that easily ....
  in about 2-3 weeks part time. lol
  
  Great work Burn, you're rolling on it.
  Rock Onward and Upward man !
  
  New intake looks mighty Wicked.
  Bonus points on the cool factor even if nothing else.
  
  3 questions:
  
  1.What did you use to get the deck/chambers on the head so clean ?
  
  2.Is the exhaust going to grow another leg - or is it staying short ?
  
  3.Is my TD airbox going on this project ?
  Please say NO !
  
  Helluva throwdown for a weekends work, should be good deal more of Go in the pedal when its back in 1 piece.   ^5
   
  
  
• #3 by the caveman on 04 Jul, 2010 10:00
• Wow Tyler that's great you got started on your Golf. Glad you also found the 1Y intake. I finally got mine from Poland[ 8 weeks in transit] and will be hooking it up once i get the Donaldson air filter mounted. Mine didn't have the EGR inlet however and so will need minimal if any cleaning. I never pulled a motor to change a rack though !
• #4 by burn_your_money on 04 Jul, 2010 11:13
• Quote from: 8v-of-fury on 03 Jul, 2010 20:49

  Wanna port my 1.6 head? 
  

  
  No
  
  

  Quote from: Baron VonZeppelin on 04 Jul, 2010 09:48

  1.What did you use to get the deck/chambers on the head so clean ?
  
  2.Is the exhaust going to grow another leg - or is it staying short ?
  
  3.Is my TD airbox going on this project ?
  Please say NO !
  
  

  
  1. A machined flat 9X9 chunk of steel and sandpaper. I think I used 4 sheets of 400 grit and then a final sheet of 1500. I spent close to 45 minutes just sanding.
  2. I have a full exhaust on my car now. It has 2 mufflers though so I might be changing it all around again.
  3. Nope, I have a mk2 air box I'll be using. Yours is safe.. for now

  Quote from: the caveman on 04 Jul, 2010 10:00

  I finally got mine from Poland[ 8 weeks in transit] and will be hooking it up once i get the Donaldson air filter mounted. Mine didn't have the EGR inlet however and so will need minimal if any cleaning. I never pulled a motor to change a rack though !
  

  
  Glad to hear yours arrived. You'll want to enlarge the ports on it to match the head. They are very tiny for some reason.Any more info on this Donaldson?
• #5 by burn_your_money on 04 Jul, 2010 14:34
• I got a bit more done today. I drove around for 4 hours picking up a dual headlight setup and G60 valve cover. I sandblasted and primered the valve cover but I don't know what color to paint it. There are far too many choices out there. I also drilled the holes in the head to secure the valve cover. I think I messed one of them up but I'll find out once I get them all tapped. I guess worse comes to worst I'll just drill out the hole in the valve cover a bit and run a washer.
• #6 by Baron VonZeppelin on 04 Jul, 2010 21:06
• Quote from: burn_your_money on 04 Jul, 2010 11:13

  I have a mk2 air box I'll be using.

  
  You gonna knock the bottom outta it -  or poke any holes in the side of it ?
  
  

  Quote

  ...drilled the holes in the head to secure the valve cover

  
  That is hardcore doing it up right there by golly.
  
  

  Quote

  Yours is safe.. for now

  
  ahem.... whew that was a close one - lol.
  Thanky 
• #7 by tSoG-84bit on 04 Jul, 2010 23:36
• Quote from: burn_your_money on 04 Jul, 2010 14:34

  I don't know what color to paint it. There are far too many choices out there.
  

  
  hot pink. if anyone ever questions it, simply mutter something about the car being the boss, and she has better taste.
• #8 by burn_your_money on 05 Jul, 2010 22:02
• Hot pink... I like it lol
  
  So major oversight on my part. I decided to go with the fiber headgasket. I ordered it and it came in and I went to fit it when I realized that the bores are different diameters. Yep, sure enough the pistons hit the headgasket. Now I need to use the metal one which really worries me. Last time I did this with this much warpage it didn't seal. I just finished putting the head all back together too  
  
  I got the G60 valve cover to fit. Turns out I misdrilled 6 of the holes and had to slightly enlarge them in the valve cover. No big deal as far as I can see.
• #9 by rabbitman on 06 Jul, 2010 08:33
• You can't get a fiber gasket for the AAZ?
• #10 by Baron VonZeppelin on 06 Jul, 2010 08:36
• Hylomar or some copper coat headgasket spray is about all thats left. Ask a blessing - pray and torque. Return thanks if it holds.
  
  Its getting almost impossible to touch anything without it getting collateral complications or snowballing. Just keep marching soldier.  
• #11 by burn_your_money on 06 Jul, 2010 08:46
• Quote from: rabbitman on 06 Jul, 2010 08:33

  You can't get a fiber gasket for the AAZ?
  

  
  I tried to get one for a 92 Passat AAZ which originally came fiber (so I'm told) but it was the same p/n as the metal one. I think I'll suck it up and get the head machined.
• #12 by burn_your_money on 06 Jul, 2010 15:11
• Good news or bad news... good news or bad news...
  
  Lets go with the good news first.
  
  I got my valve cover to fit and gave it a few coats of paint. I think it's pretty snazzy.
  
  
  
  And now the bad news. The warpage was really scaring me so I bit the bullet and decided to get the head machined. A called around to a few shops and found one that sounded like he knew what he was doing. He's done lots of them, yeah no problem, bring it in, $75. It'll take an hour.
  
  So I pull all my valves out (again) and 30 minutes of driving later I am at his shop. I hand him the head and pull up a seat. 2 hours later (at closing time) he comes up and says "I can't charge you for this". Never, ever what you want to head a machine shop say. Apparently my head was funny and his machine didn't like it and it kept chattering. They couldn't get a decent surface. They've taken off 0.005". He told me of another shop that has a different machine so I will try there tomorrow.
  
  
  
  It was hard to get a decent picture and I was using Giles's camera which I am unfamiliar with.
• #13 by burn_your_money on 07 Jul, 2010 18:02
• So I brought my head to the other shop and thankfully they knew what they were doing.
  
  
  
  I never really liked that my pump was just a turned up 1.6 pump with 1.9 delivery valves so I decided to swap in the 1.9 NA camplate.
  
  
  
  Then it was back on the test stand for some recalibration.
  
  
  
  Thumbs up for sweet success
  
  
  
  Then off to paint
  
  Primer first
  
  
  
  Then the first coat
  
  
  
  While I had everything apart I figured my flywheel (200mm) could stand to lose a few pounds so I sent it out.
  
  Before
  
  
  
  After
  
  
  
  Before and After
  
  
  
  I hope this works
• #14 by Baron VonZeppelin on 07 Jul, 2010 20:23
• Head looks great now.
  I'ma say shop #1 was stretching the truth just to try and get the work/money.
  
  That poor flywheel sure got skinny, lol.
  
  Mk2 calibration/test machine ... what a coincidental name !
  
  Is that the main man behind all the magic (Giles) in those shots ?
  
  And what color is that you put on the pump and Vcover ?
  Light blue metallic - Pontiac engine blue ?