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91
IDI Engine / Re: Sharing my 1.6td project
« Last post by RabbitJockey on February 06, 2024, 02:01:10 pm »
i am curious what you'll get a replacement. I think the pulley is probably the problem, like it is intended for an older 17mm crank but this is a later engine, it is an 81 which was the cross over year for 11mm/12mm head bolts.
92
IDI Engine / Re: Sharing my 1.6td project
« Last post by as4k on February 06, 2024, 01:46:16 pm »
I think you need to replace that bolt with something that is longer and has a head on it that you can turn by hand with a wrench.  I have an 81 with a 17mm head on it.

Agreed.  I'll snag the correct bolt based on the parts catalog.  Just figured it was correct from when I acquired everything.
Appreciate the continued help here!! :)
93
mTDI Mechanical TDI Conversions / Re: Thoughts on mTDI AHU head porting
« Last post by RabbitJockey on February 06, 2024, 11:57:40 am »
that could be, either way it's not worth removing it completely the risk are worse than the tiny amount of flow you might gain.
94
IDI Engine / Re: Sharing my 1.6td project
« Last post by ORCoaster on February 05, 2024, 09:40:05 pm »
I think you need to replace that bolt with something that is longer and has a head on it that you can turn by hand with a wrench.  I have an 81 with a 17mm head on it. 
95
IDI Engine / Re: Sharing my 1.6td project
« Last post by as4k on February 05, 2024, 08:36:36 pm »
You should be able to get to the crank bolt with the pulleys on.

 That chain looks big enough to lift the engine, ha.

The photo I had didnt originally work so I'm reposting it.  LOL, yeah, the chain was a bit overkill but its what my friend had :D

96
mTDI Mechanical TDI Conversions / Re: Thoughts on mTDI AHU head porting
« Last post by fatmobile on February 05, 2024, 07:56:34 pm »
I think that bump helps with swirl/flow too.
97
IDI Engine / Re: Sharing my 1.6td project
« Last post by fatmobile on February 05, 2024, 07:53:11 pm »
You should be able to get to the crank bolt with the pulleys on.

 That chain looks big enough to lift the engine, ha.
98
mTDI Mechanical TDI Conversions / Re: Thoughts on mTDI AHU head porting
« Last post by RabbitJockey on February 05, 2024, 04:59:32 pm »
There is also a bump in the intake bowl that you don't not want to remove, reduce and smooth it sure but don't remove it. It's extra material around the injector boss to help prevent it from cracking. Unfortunately I removed most of that material because I didn't realize what it was at the time.
99
mTDI Mechanical TDI Conversions / Re: Thoughts on mTDI AHU head porting
« Last post by RabbitJockey on February 05, 2024, 02:48:50 pm »
check out the david vizard article stickied in the idi section, thats a great start. frank06 has explained some of what he does over at tdiclub if you search.

you can also check out some of vizards videos on youtube, try to search for some that just cover basics because he is very technical and gets into the nitty gritty.

richard holdner has a few good videos on the basics, and he is not a head porter so he literally just covers the basics.

I did my ahu head, the intakes are pretty easy, just clean up the casting in the ports and smooth out the transition to the valve seats, they're not too bad stock you dont want to do too much with out a flowbench, less is more.

the exhaust can use a lot of clean up, i'd recommend following the vizard guide for them as theyre basically the same. remember less is more, and hoggin them out kills air speed which will kill power everywhere except for high rpms
100
IDI Engine / Re: Sharing my 1.6td project
« Last post by as4k on February 05, 2024, 01:31:37 pm »
I think I was more concerned that if I needed to crank the engine by hand, I really couldnt from down there unless I took off the crank pulley sandwich.
Of course, this is just one of a handful of things I'll investigate and fix when the car is moved.
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