1.9 aaz mk3 build

[mk3pete]

Hi all im from australia iv enjoyed having a read of the info on this site, well appreciated whats available here!
Parts are hard to come by here as the idi was never released in aus
Pics for kicks
Im rebuilding my engine and need some guidance and direction.

Current MOds include
o2a conversion.
t3 turbo with 19 psi wastegate, i made the custom bracket and machined the bush to suit.
It was previously sticking and had standard wastegate. 14 psi i think


Small FMIC.. looking to upgrade?
boost pin.
played with the fuel settings, last it was running was boosting around 22psi

Plans and things to fix..

I have a big box of parts ready to go but need extensive prep work before i can start rebuilding.
head is cracked and in need of a new one. pics to follow.
will be fully rebuilt.
arp head studs to be ordered! when i pulled the head it was like undoing normal bolts with a 3/8 ratchet. :/
any pointers as what to do before i throw it in? ported or polishing any real gains to be had?
i was going to keep it standard to keep costs down.
g60 valve cover also on the ajender.

Im getting quite a lot of heat soak!!
i know i need a larger ic but was wondering if its worth the effort in running both a front mount and a water to air ic?
if so where to look for such things?

As for fueling i purchased some injectors from hans auto parts apparently an upgrade for the 1.9, mercedes i believe
part number 0432217141 pic to follow.

Injector pump hopefully will get my hands on a giles!

engine has done around 33000kms
crank keyway is in good nic but will get it machined to suit the tdi sprocket
i haven't inspected the bottom end yet but im presuming its in good nic.
If it is shall i just throw it all back together?
trying to weigh up between cost and reliability, time will tell i suppose.

At the end of the day im looking achieving  150 whp or more, no heat soak and i want it pulling hard and early with good top end.
which leads me to turbo options ??
will the t3 suffice or somthing different, more modern maybe?
i have found the t3 to be too laggy but the top end is great.
is it worth it to run a compound setup at these power levels, little to no lag with great top end?

[mk3pete]

DANG 1000kb is quite small to upload files...

[mk3pete]

More pics

[mk3pete]

More pics of the engine
this is the intake il be using sorry cant remember exactly whats its from.

[vanbcguy]

All sounds pretty good...

The 'Hans' injectors are no good, 'Hans Diesel' is the infamous Prothe, vendor of terrible China-made parts that will eat your engine.  The Mercedes nozzles are NOT a good idea for VW engines; the Mercedes prechamber design is entirely different than the VW one and the spray pattern of the injectors is not correct.  They don't create any additional power but they will make more smoke and may damage the prechamber over time.  Prothe just sells them because someone once upon a time a bunch of years ago thought they might have some power gains, however that idea has long since been abandoned.  Nobody has found a nozzle that works better than the stock ones even at much higher power levels.

The injection pump is really where most of the fueling changes need to happen - the stock pump will get you up to around 120HP or so but it has a hard time injecting the fuel fast enough to support higher power levels.  As you turn things up the injection duration gets to be too long which means you're still trying to inject fuel too late in to the cycle even with the timing as advanced as possible.  A good pump builder (Giles, Dieselmeken) can build you a pump with more suitable fueling.  Dieselmeken may be a better option for you than Giles just due to proximity (he's in Europe). https://www.facebook.com/dieselmeken

That intake is off of a PD130 or PD150 engine - it's a good intake, BUT you may have clearance issues with your turbo running the stock AAZ manifold, just FYI.  I have the same intake on my TDI build.

Turbo wise, search for Alcaid on here - he's selling some smaller Holset turbos that are much more modern than the 30-year old K24/T3 designs that you're looking at.  They're capable of much higher pressure ratios with a lot less lag.

[mk3pete]

Good to know mate will certainly be putting the standard ones back in!
As for the intake I was already running her, but yes it is an extremely tight fit, quite a task to remove the turbo.
How does the holset go as far as fitment compared to the old t3?

[RabbitJockey]

i have a similar turbo on my aaz and i did not find it to be very laggy, try adjusting the wastegate and fueling to get better spool up.  yours looks like the prothe t3 which is a little bit larger than the genuine vw t3, though its exterior dimensions are the same.  the turbo should be able to get you 150whp.

[RabbitJockey]

the holset is a much better option, but the t3 should be able to meet your goals.

[vanbcguy]

The Holset needs some custom work, it won't bolt up Yo the stock downpipe or oil lines for instance. Ping Alcaid and get his recommendations if you go that way, he's a smart dude!

[mk3pete]

My downpipe is made to suit the t3 il post a pic. Thanks for the reply guys!

[manehfr]

turbo to no lag with great top end... there is no such thing unless you are able to put a variable geometry turbo... wich you would have to put ECU ... or you could put biturbo... like k14 and a k24...

[mk3pete]

Pics of down pipe and bent rod  the rest are strait. Hopefully the cranks alright after running that rod for who knows how long.