Ok, here I go!! This build is going to take some time as I'm not in any particular rush nor am I particularly flush with cash - I have a 1-month old baby here at home and I figured I needed a project that let me have some "me" time but keeps me around the house.
Anyhow, some of you who've been on here for a long time have probably seen Jezebel Jetta... I bought her nearly 5 years ago now, she came to me with a 1.6TD engine in her bay instead of the AAZ I thought I was buying. I didn't know enough about VW diesels at the time to spot the differences. My how things have changed...
In the time that I've owned her I've cleaned up most of the crap problems that she came with - I put new coil springs in all 4 corners, brakes have been done, tires were done a few years ago, she's got a 2 1/2" exhaust system from the back end of the stock AAZ downpipe back, Bilstein HD shocks and a monster AWIC... Fixed the cruise control and the sunroof... I replaced the carpets, put down soundproofing and swapped in an interior from another Jetta that we have. So I've put quite a bit of time and effort in to her!! She's got about 330,000km on the odometer now, she had 260,000 when I got her.
I know my 1.6TD is getting a bit long in the tooth - it runs fantastically and pulls great but I figured I should either decide to buy a different car, or start working on a new drivetrain for her. Seems I'm attached to Jezebel, so I decided to start working on a new drivetrain.
I picked up an AHU a few weeks ago that I'm just starting to strip down. It came fairly complete, though the wiring harness is a bit hacked up (it was cut off at the firewall by someone a little too eager to get the engine out of the car). My plans!!
- Sell off the ECU, K03, EGR stuff, manifolds
- Get everything stripped and off to the machine shop
- Find someone to do some porting on my head
- Get all my internals together
- Get the engine built up - targeting about 150-200HP
- Get an M-TDI pump
- Get an 02A from a Mk III TDI
- Get my K24 rebuilt (or find another turbo suitable for 20-25 PSI)
- Do the swap!!
I don't have the head pulled yet so I'm holding off buying too many parts - if it turns out the block is crap or whatever then I'll be starting from zero again. The only thing I've bought so far is a PD150 intake with EGR delete pipe. But I have got my work space more or less set up, which is a great start!
Hopefully this weekend the head will be coming off and then the fun stuff starts!