Franken engine

[dieseltim]

Ok, I have lots of pieces and some machining capabilites. So, I decided to take some of the parts and see what I can make from them. So, I am going to try to fit a 1.8ltr PG (corrada) block with a 1.9tdi head and a worked over 1.6td pump and injectors turbo and intercooled. The question I have is what size are the pistons in the newer 2 ltr tdi engines? I found that the 1.8 is already bored bigger with a shorter stroke, than a 1.9 tdi. So, now I need some pistons for a diesel that will fit in an 80mm bore and give me the compression I need to make this monster run. I know from reading here for some time that I am not the only one that is trying to put together something a bit different. I am hoping to get about 2 ltrs and around 140-150hp from a non-computer engine for my 91 2dr jetta, everyday driver.

Dieseltim

[RabbitJockey]

i'd really like to see a diesel made with an aba bottom end

[16V-Sauger]

you'd better use a tall block because the longer rods can handle more pressure.
the 2l 16v tdi have 81mm bore and 95.5mm stroke, exactly the same as the 1.9l diesels.


how do you want ro reach 2l? the bigger the bore will get, the more difficult it will be to reach a good compression ratio.

cr should be >=20:1 to get a smooth idle

[BlackTieTD]

cool idea, keep us posted

[vwmike]

AAZ's used a 79.5mm bore.

[16V-Sauger]

AAZ's used a 79.5mm bore.

my fault, i should have related my words to the stroke only  :oops:

[vwmike]

AAZ's used a 79.5mm bore.

my fault, i should have related my words to the stroke only  :oops:

Not a problem, I just didn't want anyone to get confused  

[RabbitJockey]

i think that an aba with a 1.9 idi head and diesel pistons would probably be one of the most beneficial franken engines (aside from a vr6 tdi  :twisted:)  anyways especially an obd I block since it has oil squirters

[935racer]

You are going to need custom rods, don't use a gasser block, the webbing internally isn't as strong, hence why big HP gasser guys use diesel blocks. Also the 1.6td pump is going to give enough fuel pressure to make much power with the tdi injectors.

[HP]

I am going to try to fit a 1.8ltr PG (corrada) block with a 1.9tdi head and a worked over 1.6td pump and injectors turbo and intercooled.

$h!t€  :shock:  :shock:  :shock:  :shock:
Good Luck...

[dieseltim]

Ok, can anyone tell me about the pistons from a touareg tdi.  From what I have found this pistons are 80.97mm but, I am not sure if they use the same wrist pin size. Can anyone tell me where I can find 4 of them?

Thanks,
 Dieseltim

[BlackTieTD]

also, the PG blocks (G60) were made alongside the diesel blocks on the same line, with the same tooling. there are actually a number of similarities but i read that article years ago...too long to quote anything. i'll try to dig it up. essentially they did it that way so the PG blocks would be as tough as diesel blocks and they could re-use existing tooling.

[dieseltim]

Yes,
  Blacktie, I am using the PG block to start with. I have found that the v10 TDI pistons are just a bit larger 80.97mm, then the block is right now 80.00mm, so. If I could find 4 of them, then maybe I can put together a PG block with a 1.6 or a 1.9 crank and rods w/ a 1.9 td head and a worked over injection pump and oversized injectors (maybe from my old 2.3Peugo 505d). I think that would make it just over 2ltrs.
The PG has the same oilers and looks like everthing is the same as the 1.6td w/ just a larger bore. I am going to get the gauges out soon and check all the diam. and see if I can find anything other than the stroke and pistons that are different. I will post some pic in a few weeks. I am just trying to see if I can bolt together something from parts and get a bit more power without having to spend lots of $ for custom parts and machine work.
In the long run it is just for fun anyway.

Dieseltim

[BlackTieTD]

love it!

[DVST8R]

Yes,
  Blacktie, I am using the PG block to start with. I have found that the v10 TDI pistons are just a bit larger 80.97mm, then the block is right now 80.00mm, so. If I could find 4 of them, then maybe I can put together a PG block with a 1.6 or a 1.9 crank and rods w/ a 1.9 td head and a worked over injection pump and oversized injectors (maybe from my old 2.3Peugo 505d). I think that would make it just over 2ltrs.
The PG has the same oilers and looks like everthing is the same as the 1.6td w/ just a larger bore. I am going to get the gauges out soon and check all the diam. and see if I can find anything other than the stroke and pistons that are different. I will post some pic in a few weeks. I am just trying to see if I can bolt together something from parts and get a bit more power without having to spend lots of $ for custom parts and machine work.
In the long run it is just for fun anyway.

Dieseltim

Problem with that is the v10 tdi pistons are completly differnt and wouldnt even work if you were doing a tdi enigine unless you could get the injector and valves in the right spots.  :wink: