Apparently I got a little carried away this weekend

[rabbitman]

Is this done yet? Looks good so far.

Can you tell if the porting made a difference?

I'm sorta getting ready to do some gasket matching/porting and I wouldn't mind hearing a first hand account.

[burn_your_money]

Well I should probably update this thread...

I finally drove this car about a month ago. I had ended up giving the car away to my younger brother about a year ago and just haven't been home so I never had a chance to drive it.

WOW it's quick. I wouldn't be afraid to line up against any stock 1.9TD in a MK3 or possibly even a mk2. In a mk1 I might get a beating but I doubt it.

Most mildly tuned 1.6TDs wouldn't be a problem either, it could already beat them before all this work was done.

As for what mod had the most effect, I have no idea unfortunately.

I know it rattles pretty good when cold (winter cold) which is probably a combo of the porting and lightened flywheel, but mainly the flywheel I think.

The powerband feels almost exactly like a gas 1.8l 8v in stock form. Good pull all the way through the RPMs. It would be a lot quicker if I didn't have the 3.67 final in the tranny but I think it is a good trade off. My brother says the mileage is great but has not actually measured it. It isn't his first diesel so it's not he is coming from a VR or V8 or something silly like that.

It still needs a proper sized exhaust and I do have one of Dr Diesels cams sitting around in a box...

[92EcoDiesel Jetta]

Hey BYM, did they remove the pre chambers when the head was shaved down? Was process cutting (fly cutter?) or grinding (with a stone)?

Machine gray is the name of the paint

After searching the forums for hours I decided that it would be best to peen my precups since they were loosey-goosey in their holes. I placed the headgasket on the head and peened 2 areas that were inside the combustion area, away from the sealing ring on the headgasket.



Because the AAZ is a bit taller then the 1.6 I had this spacer made for the exhaust.



As you can see it was a bit too small. This fixed it





Some progress



I had to make an EGR block off plate for my intake



Luckily I don't like throwing things out and I was able to find a hose that worked perfectly for my CCV





I wanted to bolt the tranny up to the engine tonight but I noticed that my clutch push rod had extreme play in it. I had the bushing but no seal. Hopefully it will come in tomorrow and then it's time to go for a test drive

[the caveman]

looks good. but find another one of hoses for when that one gets degraded from the oil. It's a coolant hose and won't last more than a couple of years.

[burn_your_money]

Thanks. I'll mention it to my brother since this is his car now.

[R.O.R-2.0]

isnt it a 16v heater hose or something? with one elbow cut off?

[burn_your_money]

isnt it a 16v heater hose or something? with one elbow cut off?

Unlikely, I only play with diesels so it's probably off a 1.9 or 1.6 TD

[R.O.R-2.0]

isnt it a 16v heater hose or something? with one elbow cut off?

Unlikely, I only play with diesels so it's probably off a 1.9 or 1.6 TD

i swear to you that its the EXACT same shape as the 16v heater hose i put on my car not long ago..

[burn_your_money]

VWs are like legos 

[R.O.R-2.0]

VWs are like legos 

Indeed 

[burn_your_money]

Ok so 120 000kms later she's still running just fine. My brother does pizza deliveries so he racks up the miles. He still hasn't done a proper mileage test but this weekend for my sisters wedding he drove 4 hours highway fully loaded, tail dragging and only used 1/3 of a tank. Hopefully he gets some real numbers soon but I'm not counting on it.

[Rising]

This was in a mk2 right? What all was done besides the porting and the flywheel and dual port header? Gov mod? Fuel?

I'm really tempted to pull out my head when I do the turbo install and do some work on the exhaust ports. Also considering porting this Gasser intake manifold. Would I notice basic gasket matching like you did? On a n a? What about a TD?

Sent from my ADR6400L using Tapatalk 2

[theman53]

See the IDI section. There is a sticky called do it yourself porting, David Vissard or something similar. The exhaust side is little gains. The intake side is where it is at. Read it all 4 times and it will start making sense.

[Rising]

See the IDI section. There is a sticky called do it yourself porting, David Vissard or something similar. The exhaust side is little gains. The intake side is where it is at. Read it all 4 times and it will start making sense.

Yes sir! I have read through that once but as you said it was a bit over my head. I will endeavor to read a few more times and get it down.

Thanks!

Sent from my ADR6400L using Tapatalk 2

[burn_your_money]

This was in a mk2 right? What all was done besides the porting and the flywheel and dual port header? Gov mod? Fuel?

I'm really tempted to pull out my head when I do the turbo install and do some work on the exhaust ports. Also considering porting this Gasser intake manifold. Would I notice basic gasket matching like you did? On a n a? What about a TD?

Sent from my ADR6400L using Tapatalk 2

It was done in a 90 or 91 Golf. It has a Giles pump and a 1Y intake manifold.

Most of the work needs to be done on the exhaust side if you are just gasket matching. The intake line up very well. I'm in the process of porting another head right now. If you run your finger in the ports exiting the head you will feel sort of a screw design in the casting. I'm pretty sure VW did this on purpose to have the air swirling in and out of the head. I simply try to smooth the rough areas and make the ports a bit bigger where possible without messing up this swirl effect.

I'm not sure how noticeable porting on it's own would be. Probably somewhat but I think even more so if you've upped the boost and opened up the exhaust.

I'm not sure if the gasser intake manifold causes the air to swirl, I know for sure that an AHU/1Z intake manifold does and I assume that the 1.6 TD one does as well. Next time I'm cleaning a intake out I'll try it on a 1.6TD manifold if I have one kicking around.