Engine is finally IN!!

[funkaholik]

Finally.  After many months of cleaning, machining, ordering parts, getting wrong parts, sending parts back and getting right parts, delays, excuses, acts of God, etc. etc., this engine is coming together nicely.
Here are some specs:

1.6 TD
Bored .5 over
New KS pistons
New head with port work
Metal headgasket
Lightened intermediate shaft
ARP rod & head bolts
Performance Diesel pump & injectors
Rebuilt K24 with Dieselicious kit
Adjustable boost controller
Overboost valve delete
Techtonics windage tray & oil pan
Pretty red paint
Polished G60 cover
Blah, blah, blah, etc., etc...

Trans is getting a .71 5th gear and a Peloquin.

Many thanks to this forum's members for all the advice, inspiration, and proper parts!  Even though it's not quite finished, I just had to share some pics:





Still have some parts left to bolt on, plus I need to figure out intercooler plumbing for my A/C MK2 Jetta.  Not a lot of room up front with the condenser there.  Anyone done this already that can give me advice & pics?

Here is the recipient:





I am so glad this is finally coming together.  Once the new engine & trans are in, she will hopefully live up to her trunk badge.  The current engine is a worn-out, oil-dripping, blue-smoke-belching, gutless little beast that somehow just keeps starting up and running. Don't know how much longer that's going to keep happening.

That's why I got the car so cheap, though.  

[RadoTD]

Oh daaamn, that's a nice looking engine! Very good work, get it on the road, blowing coal NOW!

[rabbid79]

Beautiful

[theman53]

Same build as my car except I didn't do the peloquin diff just the 80% kit, I had a good turbo not rebuilt, and I painted mine Orange instead of red. Yours looks better than mine.

[dankcorey22]

awesome build! Very perdy 

[ktzdsl]

Outstanding build. Way beyond me. What transmission code do you have for your GTD to be?

[Jory]

Is that a TopLine head or one of Prothe's?

Looks good

[gnavs]

god that's sexy

[monomer]

Oh my GODDDD


I was going to leave my frankenmotor build dirty, but DAMN!

[Alcaid]

Eye candy!!!

Did you also change the intermediate shaft bearings? If yes, was it hone/ream to fit or plug & play?

[DieselBalz]

That is one purdy engine. Lovin the GTD badge tucked under the spoiler. The G60 Valve cover looks sooo good polished. That is where I went with mine. But thats the ONLY thing shiny under the hood. 

im·mac·u·late/iˈmakyəlit/

Adjective:   

    Perfectly clean, neat, or tidy.
    Free from flaws or mistakes; perfect.

[shwak23]

What is the hole on the front of the valve cover for?

[funkaholik]

Thanks for all the compliments!  It has been a long, slow road getting it to where it is now.  I'm sure most of you can relate - everything ends up taking twice as long and costing twice as much as you planned. 

Unlike some of you amazing diesel wizards out there, most of the dirty work on this project has been done by a shop, and not by me.  Quite frankly, I don't have the equipment, time, or mad skills necessary  to make sure that this engine turns out perfect.  My hat is off to those of you that have done it all yourself, even if every part isn't polished or powdercoated.  I AM doing all the work that's in my ability, though.  Just finished putting on all 4 coilovers, and replacing all the bushings and ball joints. 

Answers to a few questions:

The trans is an AOP.  I'm replacing the .75 5th gear with a .71 while it's out for rebuilding and LSD install.

The new head is from Brazil.  My machinist sent the first one back, said it was crap.  Second one was much better.  He did a proper valve job, a good amount of port work, and installed the Dr. Diesel cam.

IM shaft bearings were replaced.  Not sure what the method was, but I trust Matt did it right.

The small hole in the front of the valve cover is a drain hole in case you are uncoordinated and spill a bunch of oil in the recess around the cap while filling it up.

For reference, here is what the engine that's in there now looked like when I got the car.  It was originally an 8V gasser automatic.  Previous owner paid $4500 for a shop to do a diesel and 5 speed swap (I have the receipt!) in Nov. 2007, and this is what he got.  Wires everywhere, coil and computer still there, leaking and burning oil. I bought it 3 years later for $1950. I especially like that someone repeatedly used a prybar on the radiator support to tighten the alternator.



And, since you all liked it, some more eye candy...

[monomer]

Is there a part number for that timing cover backplate?

[funkaholik]

Timing cover backplate - I will check for a part #.  I got it used, then stripped and powdercoated it.