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Engine Specific Info and Questions => TDI Engine -General Info => Topic started by: scopefrfd on September 06, 2005, 10:05:58 pm

Title: mechanical injected tdi running
Post by: scopefrfd on September 06, 2005, 10:05:58 pm

I finally installed my 01 ALH tdi in my 92' jetta.  Specs: 01 ALH 39K miles, 1.6td KKK turbo, AAZ intake manifold, 11mm mechanical injected pump from I believe a Fiat.  Auto tdi injectors as a baseline.  Complete intercooler setup from a A2 golf GTD.

 Took the glow plugs out primed the pump, tightened the injectors lines and glow plugs, and the engine fired right up without any hesitation or help from the glow plugs.  Engine was completely cold, very impressive.  Seems to run very nicely although the exhaust is not hooked up so it's a little loud.

I installed a CTN 02A tdi tranny and a complete plus 1, 5 lug suspension setup from a corrado vr6.  Brakes, disc all around w/ 11" front rotors and audi dual piston front calipers, upgraded MC.  

Hopefully, I'll be able to road test it this week.  A lot of little things to sort out.  If anyone is interested I'll keep you posted.

Title: mechanical injected tdi running
Post by: VWRacer on September 06, 2005, 10:25:57 pm

Quote

If anyone is interested I'll keep you posted.

Rock on, Bro! There is nother here but love for all things VW diesel...  :lol:

Title: mechanical injected tdi running
Post by: AntonUK on September 07, 2005, 05:27:51 pm

wow sounds awesome! Which audi calipers are you using? Is it the audi coupe ones? I have an audi 80 and they run same calipers as g60 as far as I can figure (or very similar mII type) they are 180mm. I really want to run them on my late A2 16v gti hubs but havnt got round to seeing if the caliper holes will line up.

Title: mechanical injected tdi running
Post by: aidan on September 18, 2005, 06:15:09 pm

Any idea which fiat the pump is from?

Title: mechanical injected tdi running
Post by: scopefrfd on September 20, 2005, 08:04:47 pm

I finally took the car for a short ride and the cars comes on boost very quickly, set for stock boost levels 12psi........no tach hooked up yet.......engine runs very cool, maybe caused by the automatic tdi injectors and 2.25" exhaust.   One thing I have noticed is the governor is coming in too early to unlock the potential of the motor/turbo setup.   the 11mm pump was for a fiat truck I believe and the governor needs to be modified/removed.  The ALH engine with mechanical pump is a tight fit in an A2 jetta....pump boost aneroid comes very close to the hood.  

Once I finish installing lights and such I'll be ble to take it for a good ride to get a better feel.  The plus one corrado vr6 front suspension and audi dual piston brakes are absolutely fantastic.  I ended up using passat vr6 springs all around and trimmed them to get the ride height to approx stock level.  The car actually is very close to stock ride height maybe a hair lower, but it corners like it's on rails and the brakes are simply awesome....great modualtion.  To say I'm pleased so far would be an understatement

Title: mechanical injected tdi running
Post by: scopefrfd on September 20, 2005, 08:07:36 pm

Quote from: "AntonUK"

wow sounds awesome! Which audi calipers are you using? Is it the audi coupe ones? I have an audi 80 and they run same calipers as g60 as far as I can figure (or very similar mII type) they are 180mm. I really want to run them on my late A2 16v gti hubs but havnt got round to seeing if the caliper holes will line up.

the audi calipers are from an audi turbo...dual piston they are stamped Girling "60" on the caliper and are dual piston.  The stock vw corrado calipers are Girling "54" single piston...are very good caliper, but I got a great deal on the dual piston ones so I had to put them on.

Title: mechanical injected tdi running
Post by: GTIMINI on September 20, 2005, 09:12:48 pm

Quote

the audi calipers are from an audi turbo...dual piston they are stamped Girling "60" on the caliper and are dual piston. The stock vw corrado calipers are Girling "54" single piston...are very good caliper, but I got a great deal on the dual piston ones so I had to put them on.

That is from the Audi 5000 Turbo right?

Title: mechanical injected tdi running
Post by: MacGyver on September 21, 2005, 08:55:17 am

What year Passat springs did you use?
I presume you had to trim a substantial amount off the rears?

Title: mechanical injected tdi running
Post by: scopefrfd on September 21, 2005, 01:21:56 pm

Quote from: "MacGyver"

What year Passat springs did you use?
I presume you had to trim a substantial amount off the rears?

I think the springs were from a 1993 B3 passat VR6.  The fronts maybe a full coil...and the rear it was maybe two coils...I have FK rear shocks w/ adjustable perches.  The coils were cut with a cut off wheel and I had the springs sitting in a bucket of cold water to keep the metal cool.  THe spring rate is just about perfect...firm but not harsh and it still has the full travel for these awful massachusetts roads.

Title: mechanical injected tdi running
Post by: JKnowledge on September 22, 2005, 08:28:46 am

What ECU are you using with that setup?

Title: mechanical injected tdi running
Post by: scopefrfd on September 22, 2005, 01:43:34 pm

Quote from: "JKnowledge"

What ECU are you using with that setup?

no ecu...I'll try and post some pics tonite

Title: mechanical injected tdi running
Post by: scopefrfd on September 22, 2005, 07:51:30 pm

I took some pics with the intercooler setup..but I do not have or setup any web hosting.  Sad but I'm pretty much a computer dummy.  If anyone wants to host them I can send them to you.

thanks

Title: mechanical injected tdi running
Post by: jackbombay on September 22, 2005, 09:47:48 pm

Quote from: "scopefrfd"

I took some pics with the intercooler setup..but I do not have or setup any web hosting.  Sad but I'm pretty much a computer dummy.  If anyone wants to host them I can send them to you.

thanks

  Send them to me and I can host them, PM sent.

Title: mechanical injected tdi running
Post by: jackbombay on September 22, 2005, 11:39:19 pm

PICS!

(http://img162.imageshack.us/img162/6956/10vx.jpg)

(http://img162.imageshack.us/img162/6103/24px.jpg)

(http://img162.imageshack.us/img162/2172/38iy.jpg)

(http://img162.imageshack.us/img162/3967/47fz.jpg)

(http://img162.imageshack.us/img162/6089/59fa.jpg)

(http://img162.imageshack.us/img162/3098/64zr.jpg)

(http://img162.imageshack.us/img162/9002/72ur.jpg)

(http://img162.imageshack.us/img162/5975/81kq.jpg)

Title: mechanical injected tdi running
Post by: dubCanuck1 on September 23, 2005, 12:02:58 pm

I want that intercooler!

Title: mechanical injected tdi running
Post by: tammons on September 24, 2005, 06:55:46 pm

So is that pump/shaft etc. strong enough to handle DI pressures. I have been kindof thinking about using a stock VW TDI marine pump, but I have yet to locate one.

Title: mechanical injected tdi running
Post by: scopefrfd on September 27, 2005, 10:30:37 pm

Quote from: "tammons"

So is that pump/shaft etc. strong enough to handle DI pressures. I have been kindof thinking about using a stock VW TDI marine pump, but I have yet to locate one.

The pump came from a TDI engine.  In europe they used mechanical pumps on tdi cars and trucks in the early going.

Title: mechanical injected tdi running
Post by: RabbitGTDguy on September 30, 2005, 06:41:58 pm

TDI Marine pumps are very expensive, and very hard to come by. From what I've been able to find out about them as well they are nothing really more than the same pump that was run on the late IDI 1.9AAZ motor, turned full tilt...

scopefrfd :Congrats on your mechanical TDI! I'm working on mine now and I'm glad to say that my pump choice having been able to have a friend test it is going to BE AWESOME :)

Joe

Title: mechanical injected tdi running
Post by: jos_br on October 07, 2005, 07:02:30 am

I drive a VW Caddy 1 with a mechanical pump (12mm). I use the intercooler from a Mercedes Sprinter and special nozzles (Frattelli 0,260mm). Specs.208hp and 480nm. The brakes i use are 312mm. (Audi TT)

Jos.

Title: mechanical injected tdi running
Post by: VWRacer on October 07, 2005, 09:44:33 am

Those are very impressive numbers, Jos. Can you tell us more info about your Caddy and show us some pics? Where are you located?

Title: mechanical injected tdi running
Post by: jos_br on October 07, 2005, 10:28:18 am

I am located in Holland and it takes my 4 years to get those specs out of this engine.

Jos.

Title: mechanical injected tdi running
Post by: jos_br on October 07, 2005, 10:30:02 am

Look here.http://vwcaddyforum.com/showthread.php?t=6054

Jos.

(The blue caddy).

Title: mechanical injected tdi running
Post by: VWRacer on October 07, 2005, 10:44:43 am

Holy cow!  :lol:

A caddy bed grafted onto a Jetta...how trick is that!?  :wink:

Jos, are the engine internals stock? Are you still running a K24 , or is the 208 hp with the new roller bearing turbo?

Please tell us more.

Very cool!  8)

Title: mechanical injected tdi running
Post by: jos_br on October 07, 2005, 11:38:16 am

The car is build out of two cars,a Jetta and a caddy so the car is 22cm longer than usual. The engine was running with the k24 208hp and is now running with a adjusted rollerbearing turbo but the outlet is not good, so it must be adjusted agian.

Jos.

Title: mechanical injected tdi running
Post by: VWRacer on October 07, 2005, 01:03:23 pm

208 hp on a K24...very cool!  :D

Are the engine internals (pistons, rods, etc) stock or stronger aftermarket pieces?

Title: mechanical injected tdi running
Post by: jos_br on October 07, 2005, 02:17:43 pm

The onley things i've changed is a lowered compression and i have used other bearings (not piston). The k24 was also adjusted (stronger bearing) but not good enough, i have "used" four of them............

Jos.

Title: mechanical injected tdi running
Post by: RabbitGTDguy on October 09, 2005, 06:14:31 pm

Quote from: "jos_br"

Look here.http://vwcaddyforum.com/showthread.php?t=6054

Jos.

(The blue caddy).

MMM.... that looks nice. Most impressed with the bodywork that was done. To the unknowing, probably even "knowledgeable" VW eye I doubt you could tell the differences in the length, etc. At least from the pics I see... Very nice job Jos.

Title: mechanical injected tdi running
Post by: lord_verminaard on October 09, 2005, 07:10:13 pm

Wow, beautiful Caddy!  :)  Really nice numbers too.  :)  Do you by chance have a dyno plot?  If not, do you know roughly what RPM peak hp is?  There is not a lot of people out there with hopped-up mechanical TDI's like yours so I'd like to know what the power curves are like.  Thanks and great work!

Brendan
84 Scirocco 8v
00 Camaro L36 M49

Title: mechanical injected tdi running
Post by: jos_br on November 16, 2005, 01:40:42 am

From another site, it's my car.
http://www.tdiclub.nl/topic.asp?whichpage=1&TOPIC_ID=13477&FORUM_ID=4&CAT_ID=2&Forum_Title=Motorisch+tunen&Topic_Title=Vermogen+meten+op+rollenbank
Also some dyno plots from another car we have tuned. I'm not satisfied with the turbo and i will try to make some adjusments to the feulpump.

Jos.