Vanbcguy's M-TDI Build

[bbob203]

So I had an idea the other day to integrate into a standalone control adding a circuit of sorts to use the vacuum on the cruise system to bump the idle when the engine is cold say raise it up to 1200 rpm then when the engine is at 120f it cuts off. I'm no electrical wiz so I don't know what it would take but seemed like a cool idea.

[vanbcguy]

Hmm on a mk2 you could definitely do that.... Wouldn't be hard at all really!

The cruise system on the Mk3 is a bit different. The vacuum actuator is up in the dash connected to the pedal itself. There is a separate electric vacuum pump in between the inner and outer fenders, the cruise control module commands it. So it would be a bit trickier...

If you did go that route I'd definitely maintain the brake / clutch vacuum dump valves that the factory cruise system has for safety reasons. Though that might kind of defeat the purpose since you'd only be able to control idle with the car in neutral and no foot on the brake. Would be fine for warmup though.

As soon as the controller can cause the engine to accelerate when you may not want or expect things get much more safety sensitive.

[vanbcguy]

ALH timing pulley with hub...

[vanbcguy]

Machine shop has checked everything out...

- Crank is absolutely perfect, still at factory spec and cleaned up 100%
- Head is good, no cracks, needs valve guides (duh)
- Block is good, no cracks, bores worn to about 50% of wear tolerance, going to go for the first oversize (.5mm over)

Pistons and rods should be here today/tomorrow, bought a set of ASV pistons.  Decided I'm going to have the shop do the bottom end - while I'd get a lot of personal satisfaction from doing it myself I will feel more comfortable having them do it.

Dug out the transmission I bought back at the beginning of the year - looks like there are some parts missing from the shift tower.  I had been waffling on whether or not to use the 02A stuff or if I should go straight to the 02J version, decided to go for 02J stuff rather than try and source parts for the 02A tower.  Ordered a Polo shift box housing so I can swap the 02J parts in while still fitting my Mk3 properly.  Here's the link to those if anyone is contemplating doing the same:

http://www.europeanperformanceproducts.com/shop/product_info.php/info/p11274_02M-and-02J-Transmission-Shifter-Conversion-Kit.html

That means I've got an 02A shift box and cables spare if anyone needs them for anything...

I think I'm past the half way point for money spending now thankfully.  I got put in to an 'acting' manager position at work for the next 3 months which comes with some extra $$$$ so that will help big time. 

Biggest ticket remaining items will be injectors and clutch.  Having a hard time finding big enough nozzles!

[vanbcguy]

Ha, as soon as I post FedEx shows up...



Insanely fast shipping from Boraparts.  I ordered these YESTERDAY and they're on my table here in Canada today...

[vanbcguy]

Nothing but good news from my machine shop - they're nearly done and they're on budget.  Woohoo!!

Now the transmission shop on the other hand... Not sounding so good.  My "good used" transmission is sounding pretty roasted.  All synchros shot, 5th gear shot, input bearings shot.  Going to be expensive!

[8v-of-fury]

Omg... thats brutal news.

"Good used" sketchy pickings. Lol

[vanbcguy]

Omg... thats brutal news.

"Good used" sketchy pickings. Lol

Yeah overall not really that impressed.  But I bought the thing over 6 months ago so not really much recourse.  It probably drove ok in whatever it came out of but it seems like it probably was half low on fluid and it had never been changed.  Really though, what do I do right? Start over with another transmission? I'm already in the purchase price + shop time on this one, if I throw it away and start over I'll already be in the hole.  Might as well get 'er done.

Still a lot better than the 020 that's in Jezzie right now - it has fried synchros and a giant hole in the diff casing.

[bbob203]

It will be nice to have it rebuilt w/ the lsd to boot!!

[vanbcguy]

Yeah I'll have darn near a brand new transmission when this is done... All new bearings, all new seals, new 2nd gear synchro hub, all new synchro rings and probably a good used 5th gear from another 02A.  Oh and yeah the LSD.  This bloody transmission will probably have me for over $3k though by the time it's all done and dusted, and that's NOT including the clutch / hydraulics, that's still to come.

BUT I'll have something that I can actually rely on with a warranty!!

I made the mistake of totalling up everything I've spent so far.  Don't. Even. Ask. 

[vanbcguy]

Well some good news on the transmission front... The shop decided it'd be easier for everyone involved to just sell me a rebuilt transmission rather than trying to fix the one I have.  Basically they only thing they're reusing is my transmission case and the LSD I bought.  Price comes down by about $500 as the parts cost is a lot less - works for me!!  Very glad that I'm working with a nice honest shop who is actually looking out for me.

[One_punchmachinegun]

Nice!!

[bbob203]

Nice!!

[vanbcguy]

Machine shop called, my engine is ready for pickup!! I had them build the bottom end - figured by the time I bought the tools required I'd be up at the same point as just paying them to do it, plus they are giving me a warranty on their work.  No brainer...

Now to try and find someone to come with me and pick her up!! 

[libbydiesel]

An AHU/1Z bottom end is not overly heavy.  Without a head on it, I haven't felt the need for another person.