M-TDI Build need Help

[GEE-BEE]

Okay I found a 1998 AHU motor

Iam going with a 12mm mech pump from Giles or new from this supplier

http://advancedautomotion.com/shop/product_info.php/cPath/49_118/products_id/109

Giles informed me I will need three pumps

1.6 & 1.9 AAZ and TDI to make a custom

What exhaust manifold and turbo ?

PD130 intake ?

I welcome your replys

Body will be a MK1 caddy

[vanbcguy]

The Advanced Automation pump has a farily low RPM governor FYI.  It has a nice 12mm head but its governor isn't really suitable for a light vehicle.  It is called a 'low smoke' governor and is designed for a larger engine in a heavy vehicle with a low max RPM range.  You can buy one and send it to Giles to have him do the governor though if that's the route you want to go.  The price is pretty good for a new pump.

If you are dead set on a 12mm pump you can also check out Westyventures.  Karl has been making 12mm pumps from Cummins pumps similar to what Libby was doing.  http://westyventures.com/

Of course we're all going to tell you to get the Rover pump though... It is an 11mm instead of 12mm but an 11mm head is good for well over 200HP, plus it will happily rev higher than a 12mm head will.

I used a Land Rover Defender 300TDI pump from a vehicle that has EGR.  Land Rover part is ERR4046.  It comes with a TPS already on it if you choose to go electronic for a VNT controller, or if you have some other need for a TPS (water/meth injection, fancy pedal position bar graph, whatever).  If you don't care about the TPS the non-EGR version will work fine, or any of the 200TDI ones.  I bought a Bosch reman from British Atlantic, though I notice they are out of stock right now.  http://www.roverparts.com/Parts/ERR4046

If you want a wastegate turbo I'd think the Holsets that folks are using around here would probably be ideal.  If you want to go VNT then the GTB1756VK or GTB2056V would be great.  The GTB1756VK is good for a bit over 200HP while maintaining good low RPM spool.

I used the PD150 intake on mine, though if I had the skills and time I'd look at making myself a log style manifold. 

I'm using a 2005 Passat manifold.  It mounts the turbo reasonably high up the block so it clears the Mk2/3 engine mounts no problem, though there is not much firewall clearance - not sure how that would fit in a Mk1. It has a flange that is "close" to the GTB flange though it still needs an adapter.  The adapter is commonly available though - Darkside Developments have them.  I got mine through 'X-Man' on TDIClub along with my turbo.

[GEE-BEE]

I will go with a 11mm assys than

Where can I find ?

I found a ahu on a pallet for 1k, I might have to use a aaz exhaust manifold and a pd130 intake
KO3/KO4 hybrid has been good to me ?

Thanx Bubba

[CRSMP5]

Across the pond.... Uk good place to start... When i know uk guy going back, ill be getting stash to reseal and prep for vw m conversions...

[GEE-BEE]

I found a pre-made caddy wiring harness for a ALH

ALH are easier to find , I will delete the EGR and the PS pump

Iam going to purchase a egr delete and race pipe kit

Bought a pd150 intake from the u.k. for 120.00 shipped

I will get a new vnt17 turbo or something from Jerry at GPOPSHOP.COM

N75 psi controller , 56.00

new electric pedal assy

Thanx everyone..

[burn_your_money]

If you are going mTDI what do you need the harness for?

[vanbcguy]

I think he's switched gears....

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[RabbitJockey]

any build i'd be doing i'd use a holset he221w, but i'm sure tdi has a long list of vnt turbos they'd recommend.  but for how cheap the holset is, and the broad highly efficient compressor map, plus the billet compressor wheel, anti surge compressor housing and 360* bearing, in my opinion it'd be silly to consider any other turbo.

[GEE-BEE]

http://www.kermatdi.com/servlet/the-608/bosio-ulsd-1019,-nozzles,/Detail


http://www.kermatdi.com/servlet/the-8390/1749VB%2C-CNT1749VB-%2C-turbo%2C/Detail

Iam going to start to collect parts, probly just purchase a new long block..

GB

[vanbcguy]

If you are going VNT go straight to the GTB1756VK. It is a couple generations newer than the GT1749. It spools faster, has better pressure ratio capabilities and the turbine will out flow the 1749. Since you are putting everything in a Mk1 there is no downside - you already need to deal with a downpipe.

If you want new check out Darkside Developments in the UK. Ryan has lots of experience shipping to North America. If you are OK with a rebuilt turbo then look at X-Man on TDIclub. I got mine from him. Shipped here in about 2 days.

Nozzle wise - don't be afraid to go bigger. You still won't have anywhere near the smoke of a 1.6 NA. The higher "stages" Kerma is selling appear to be increased pop pressures so I'd go for a larger nozzle at closer to stock pressure if you were thinking about one of the higher stages.

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[GEE-BEE]

I purchased a used AHU with O2A trans complete for 1400.00 with ecu, wiring harness and cable shift
( Samba )

O2A will go out for LSD and OHC

Motor will be gone thru complete ohc.

Iam doing little detail like a new powdercoated alternator and most brackes will be powdercoated as I have lots of time for this

Getting a custom intercooler for the front grill and making all the silicone hoses instead of metal will be the fun part for me

GB

[theman53]

For the turbo I love the holset...That said if you go VNT I would not go so small as the 1749. I have a 2256v I am probably putting on my Jeep conversion, not because I wanted that over the holset, but that is what I had. I figured if the vanes cause it to spool faster, why not go really big? Seems that the 15 on the 01 TDI I have is too small. But it is all in what you personally like, I am just throwing that out there.

[GEE-BEE]

Justin found me a complete ALU with computer/ wiring harness etc and O2A trans

Iam going to ship the engine to him for a complete custom build

Trans will be shipped out for complete and lsd

Thanx for all your positive comments