Heres the deal, my daily driver MB TD is getting old (517,xxxkms, still tickin) and I am looking for something a little more exciting to drive. I figured I had pretty much all the major pieces needed to build a pretty exciting turbo diesel so away I go. The goal is to make 250WHP and 400ft/lbs of torque, everyday, reliably. I want to do this on a very resonable budget, no crazy maching, gonna use stock pistons etc.
I have a ALH longblock sitting in my shop, its pretty bare, but low milage and I'll come up with the rest of the parts. I also just recently aquired a TDI o2a transmission, so I will use that. I also just bought malones old 97 golf, yes the one that I put together with the 1.6/1.9 franken engine, don't worry that engine will get more freaky, just in a older and lighter chasis
The plans of as now:
ENGINE: 70,000kms on long block
Give bottom end a quick rebuild, balance the bottom end, add total seal gapless rings, machine pistons, ceramic coat tops of pistons, add arp rod bolts and main and head studs, new bearings, polish rods, powder coat block, new gaskets etc.
Head: Full rebuild, intense porting work, new valves, 3 or 5 angle valve job, one of my custom cams, my new custom tubular manifolds, upgraded valve springs(suggestions?)
Fuel injection: starting with a brand spankin new cummins 6bt pump, a used core ALH electronic 10mm tdi pump, governor and throttle assembly from a 1.6 pump, a complete 1.6td pump top, and the only 14mm custom made head in north america, thanks to red rotors for hooking that up.
Giles will be building this pump, as much as I want to build it myself I have no idea what to set the plunger prestroke and stuff at because I have no reference point, Giles is the man for this job and he can bench test it before I throw it on the motor. I will be using a high pressure lift pump to supply fuel and a large fuel cooler to keep the temps down.
Mark Malone (
www.dieselinside.com) is hooking me up with some rc520's for the injectors until someone makes something bigger and badder.
Water injection: I will build myself and will incorporate a resevoir, a high pressure pump and 4 misters, one for each intake runner, comming from something much like a fuel rail, I might try and rig up some sort of fuel pressure regulator to control fuel with boost pressure.
Tranny: I am going to swap a TDI o2a with hydraulic clutch and cable shift into the chasis originally equipped with the o2o cable clutch and rod/linkage shifter. The tranny itself has 80,000miles on it and will have to remain stock until a later date where I can dump the cash into a peloquin and a full rebuild. I am praying I do not blow it up, no drag racing for a while.
Clutch and Flywheel: Clutch is a brand new VR6 Spec stage 3 with a 6 puck solid disk, it is rated to 444ftlbs of torque, perfect! Flywheel will be a 228mm lightened and balanced.
Turbo Detail: New Passenger Performance Race series custom tubular intake and exhaust manifolds including a custom compound turbo charger setup. I will be using a precision front mount air to air aftercooler.
And heres the kicker, I want to start the engine by mid october and have it dialed and driving by the end of october, pretty hectic but I want to try anyways.
Pictures to come! Hopefully this thread will keep me focused and motivated. Feel free to comment and ask questions.