My first 1.6TD rebuild...

[tomsdubwerks]

Hi everyone my name is Tom and I'm from the UK I've been lurking on the forum for a few months now after I got a complete mk2 Golf GTD 1.6TD SB engine and gearbox very cheap from a friend. Having recently bought a mk1 Caddy truck to put this in I have found the forum an excellent source of information. I have also bought a NOS TD block, pistons and rings from eBay so I'm soon going to be getting stuck into my first TD rebuild! I have a little experience with the VW IDI TD having previously owned a 1.9TD AAZ Passat that I rebuilt the head on after the previous owner had the timing belt fail! His loss... My gain!

So my plan? Basically I'm going to university in September to study motorsport engineering so the Caddy will be my daily drive. While the 1.6 NA will do for now it has done 180k and although I have a spare 1.6 NA from a mates truck I converted to GTI power obviously as you guys know a turbo diesel is alot more fun! So the TD engine I'm building needs to be reliable but I wanna make some modest gains from the SB's 80bhp. I'm hoping a reliable 120bhp isn't out of reach.

So basically I expect the build to be...
1) NOS 1.6TD block, pistons, rings using the old SB's crank, rods, intermediate shaft and vac pump.

2) New small end bushes, thrust washers, big and main bearing shells. Not sure what to do about intermediate shaft bearings. Heard they are lined bored after installing them?

3) Check over the old SB's head and cam shaft. No problems here as I'm familiar with VW hyrdo heads. Will run the AAZ 1.9TD MLS and ARP or similar studs.

4) Hopefully my KKK K14 turbo on the SB will deliver enough boost without excessive lag for my goal. It needs new seals but a rebuild kit is £50 so if its up to the task it will get rebuilt
EDIT! My bro has suggested I use his Eaton (M62 or 65 can't remember) supercharger... Any thoughts?
 
5) EGT, Boost and tacho gauges, 2.5" exhaust, governor mod, boost pin mod, bov mod and a FMIC. Mate says he did the mods but let's just say his intercooler pipework on the mk2 donor didn't inspire me!

Anyway that about sums it up for now. My Caddy should be on the road for July in NA form. In the meantime I look forward to any input on my project and will post pics etc as I get stuck in very soon!

[theman53]

They still make reamed to fit IM bearings. Check our FAQ, IIRC it has the part #s if not I know there is a thread somewhere...long search if they aren't in the FAQ.

[tomsdubwerks]

They still make reamed to fit IM bearings. Check our FAQ, IIRC it has the part #s if not I know there is a thread somewhere...long search if they aren't in the FAQ.

Awesome stuff that makes it easier for me. I'll have a search.

[nathan_b]

This should provide you with some inspiration!
http://forums.vwvortex.com/showthread.php?5695811-Rabbit-Pickup-maxed-out-turbo-IDI-home-grown-o2a-swap!

[tomsdubwerks]

Nice truck mate... Bet that pulls nicely!!! Like the idea of a frankenmotor and if my head has excessive wear an AAZ head is a very attractive option for me. The FAQ flagged up some IM bearing part numbers to look into. Brickwerks do the unfinished ones here in the UK for under £13 but if my shaft is close to spec I'll try a get the finished ones even if I get them from over the pond. Can't wait to crack the old motor apart to see what 220k has done to it. I know it white smoked like hell from no1 and 2 as I ran it without the exhaust manifold and turbo. I suspect injector or head gasket to be at fault but time will tell.

[R.O.R-2.0]

Nice truck mate... Bet that pulls nicely!!! Like the idea of a frankenmotor and if my head has excessive wear an AAZ head is a very attractive option for me. The FAQ flagged up some IM bearing part numbers to look into. Brickwerks do the unfinished ones here in the UK for under £13 but if my shaft is close to spec I'll try a get the finished ones even if I get them from over the pond. Can't wait to crack the old motor apart to see what 220k has done to it. I know it white smoked like hell from no1 and 2 as I ran it without the exhaust manifold and turbo. I suspect injector or head gasket to be at fault but time will tell.

the ream-to-fit bearings seem MUCH better..

the pre-sized ones are affected by how well they are installed.. if you dont install them perfectly square to the block, they wont be the right size when you are done..

it doesnt take much for your engine to have a tight bore, and squish the bearing just enough that its not pre-sized anymore..

yes, ive seen pre-sized bearings need reaming even..

so, i would just get the ream to fit one, if you can get it cheaply, then you KNOW that its the right size for your shaft, and not too tight.

[tomsdubwerks]

the ream-to-fit bearings seem MUCH better..

the pre-sized ones are affected by how well they are installed.. if you dont install them perfectly square to the block, they wont be the right size when you are done..

it doesnt take much for your engine to have a tight bore, and squish the bearing just enough that its not pre-sized anymore..

yes, ive seen pre-sized bearings need reaming even..

so, i would just get the ream to fit one, if you can get it cheaply, then you KNOW that its the right size for your shaft, and not too tight.

That is a very good point! Just means finding a decent machine shop and the best local guy has retired.

On the good news front, posting today got me all fired up and I had to take a look inside the motor so the head and injection pump are now off! Pics to follow...

[tomsdubwerks]

Start of the build I guess... Teardown!

Dragged it out corner.
 

Cam cover off. Surprised how clean it was in here!
 

Manifolds off. Inlet wasn't bolted up that tight and gasket appeared to be newish. Inlet manifold was spotless inside, as was the inlet ports. I believe some has had it off to remove the gunk like we did to a Ford Escort TD a few years ago. Massive improvement!
 

Head off. Very mild cracks between the valves as normal! Will get my bro to check that its true and skim if required. He works at a reputable tuners shop that does headwork.
 
 
  
And the best bit? Obliterated head gasket! Maybe lack of compression cause the white smoke on 1 and 2. Was running more boost than stock but I don't know what he said it was running!
 

One very happy dubber here.

[tomsdubwerks]

Took my new block out of it's wrapping today and discovered it has a pair of IM shaft bearings fitted! Fingers cross my shaft suits them!

[tomsdubwerks]

Bad news this evening but a solution was found! When I undid the crank bolt I noticed that no1 and no2 pistons did not protrude the deck. Pic of no2 v no3
 

Due to two rods like this...
 

But vagcat says the JK code N/A has the same rods and crank so my spare engine will give those up. It's a good runner so they should be fine at 140k I hope!

Also found twisted oil return from my turbo when I removed the mk2 engine mount.
 

Probably when the sump was removed by the previous owner to do this extra oil return from a catch tank! Badly!
 

Also my bro decided not to us his Eaton M62 (iirc) supercharger on his Honda project and suggested I use it on this. Very tempted to use it!

[libbydiesel]

The bent rods might be from the coolant pouring into the cylinders.

[tomsdubwerks]

Very true. At least I have replacements in the N/A engine that I swapped with my mate for some obsolete computer parts that were off in the skip anyway. 

[R.O.R-2.0]

idk if anyone has touched on this, but the stock crank nose, and crank sprocket are WEAK. nowheres near strong enough to drive a supercharger, not even a little guy like what you got. once you twist the crank sprocket out of time, its lights out for the engine. the valves get friendly with the pistons, and then that head is potentially toast..

be sure to take this into consideration before supercharging..

Andrew (libbydiesel) has made up a broach, and fixture for it, so that the crank can be broached in the car, without much disassembly..

you can broach the crank, and use the TDI crank sprocket, thats much tougher..

[tomsdubwerks]

idk if anyone has touched on this, but the stock crank nose, and crank sprocket are WEAK. nowheres near strong enough to drive a supercharger, not even a little guy like what you got. once you twist the crank sprocket out of time, its lights out for the engine. the valves get friendly with the pistons, and then that head is potentially toast..

be sure to take this into consideration before supercharging..

Andrew (libbydiesel) has made up a broach, and fixture for it, so that the crank can be broached in the car, without much disassembly..

you can broach the crank, and use the TDI crank sprocket, thats much tougher..

That crossed my mind I must admit. I think the turbo will be staying as I've seen a few dead AAZ's due to the failure. I guess the 1.6 is just as prone if you go serp belt setup too even without a supercharger?

[410]

Is it just me or does the number 4 cylinder have a crack between the prechamber and the exhaust valve?  I hope it's just an illusion?