Recent Posts

21

TDI - VE Pump TDI Engines / Re: TDI Swap on 020 Gearbox

« Last post by chi1337 on March 31, 2024, 02:44:09 pm »

hi, thanks , yeah I suspected as much since a tuned AAZ will make more torque than a stock AHU. Just the RPM range is different.

I'm going to buy a 2nd hand Golf GTD gearbox (020, 3.941 final drive, only 30 bucks lol), then I can mount up everything, starter, etc etc, and test it at home on the engine stand, so it works perfect. I'll use a new 210mm pressureplate & flywheel.

Then swap out the old engine & gearbox out in 1 go. Will salvage the old 020 for spare =)

Shopping list:
- Wiring loom ($75 for electronic throttle, n75, injection pump connector, cranskahft connector, injection sensor connector, map sensor connector)
- $20 for 1.5mm2 wiring
- Gearbox $20
- Engine $100
- Alternator, starter, battery: $50
- 210mm flywheel & plate $66
- Timing belt stuff $35
- Other stuff $50

+- 500$ total (Im in Europe so price in euro)

22

TDI - VE Pump TDI Engines / Re: TDI Swap on 020 Gearbox

« Last post by RabbitJockey on March 29, 2024, 02:22:34 pm »

most people dont know what theyre talking about. An 020 can handle a slightly modified tdi just fine as long as you use a good clutch.

the thing is that spending the money on a good clutch is money that may be better spent on an 02a or 02j. It's up to you since it's your car. 020 will work, 02a/j is better no doubt. I bought a spare 020 and used the 020 with my swap it's easier and cheaper. worst case i have to swap in another 020 that paid $100 for.

23

TDI - VE Pump TDI Engines / TDI Swap on 020 Gearbox in MK1 RABBIT

« Last post by chi1337 on March 29, 2024, 09:22:38 am »

TDI SWAP THREAD

==================
Looked around a lot, the opinion of people is that the 020 gearbox cannot handle all that torque.

For reference, the AAZ & 1.6TD uses the 020 gearbox, and produces 111 lbf⋅ft of torque. 1.6TD is nearly the same: 112 lbf⋅ft

The ALH/AHU generates 154 lbf ft if I look at this Malone chart:

https://www.cascadegerman.com/wp-content/uploads/2015/06/Malone-stage-I.png

However, the AAZ produces 150 lbf ft +- too, if it's tuned to 90 horses:
https://www.thesamba.com/vw/gallery/pix/1559156.jpg
So nearly exactly the same as the ALH, however the torque is produced at higher rpm and for a longer time.

I was thinking, while running the electronic TDI, I can reduce fueling in the 2000-3000 rpm range, so that torque bulge /spike there doesn't happen [VAGEDCSuite supports this]. Yeah kind of defeats the purpose of a TDI, but more fuel efficiency & more modern platform

24

IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting

« Last post by ORCoaster on March 28, 2024, 11:41:24 pm »

OH YEAH, I forgot about that.  Toughest thing to install on a VW I believe.  I may not be able to get one back in with the lack of hand strength these days. 

25

IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting

« Last post by fatmobile on March 28, 2024, 12:16:55 am »

And the flying flat springy thing.

26

IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting

« Last post by ORCoaster on March 27, 2024, 11:04:28 pm »

Yeah, pulling out that steering column is a bite.  Mostly due to the knuckle thing that always seems to be tighter than it needs to be. 

27

mTDI Mechanical TDI Conversions / Re: Thoughts on mTDI AHU head porting

« Last post by RabbitJockey on March 27, 2024, 01:04:44 pm »

looks good, did you do anything in the intake bowls/seat area? it looks like you opened up your exhaust more than me. i wish i had done it more like yours, but i was trying to keep it simple.

how much time did you get into it?

28

IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting

« Last post by RabbitJockey on March 27, 2024, 01:01:26 pm »

i believe there is a nice kit for the steering column bearing these days.

in the past or just for a temporary fix many just push it back into place and then use a hose clamp to hold it there.

29

IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting

« Last post by fatmobile on March 27, 2024, 02:08:23 am »

  Is the pickup AC or not?
 There is an easy way to change the heater core in an AC car.

30

IDI Engine / Re: 1.6IDI Not Fully Rotating/Not Starting

« Last post by Mohatanous on March 26, 2024, 10:19:55 pm »

Brief update:

I have not had any further work done on the head due to my friend unfortunately having a stroke. At this time we don't know if he will be alright or not, so that just plain sucks.

In the mean time I've started cleaning the block out of buildup and replacing the heater core. One other thing I have to tackle is the bearing on the steering shaft inside the car. That seems like a fun task!