VWDiesel.net The IDI, TDI, and mTDI source.
Engine Specific Info and Questions => IDI Engine => Topic started by: dillenger1 on January 25, 2008, 09:31:53 pm
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Heres the donor for the screaming bunny.1985 na hyd.head.being converted to accept tons of fuel
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel010.jpg)(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel003.jpg)(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel004.jpg)(http://i249.photobucket.com/albums/gg206/2253benjamin/generator001.jpg)(http://i249.photobucket.com/albums/gg206/2253benjamin/generator002.jpg)(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel043.jpg)
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VERY VERY COOL!!!!!!!
What a fortuitous application of our venerable 1.6!
What's the context? What are you powering and why?
-greatefuljoe
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my father had originally built the generator.He used it for power when he built his house.He eventually bought a fancy gas powered one and kicked this down to me. :D
(http://i249.photobucket.com/albums/gg206/2253benjamin/generator001.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/generator005.jpg)
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I do have some of this stuff for sale.Pick-up only.Its a 10kw generator.I may be using the fuel tank.
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel003.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel011.jpg)
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Nice setup but I don't think I have ever seen a more rusty engine!
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My dad and I really got talking about engines and generators this morning because of this thread, So I guess your taking the generator apart?
How much space did the overall design take up?
10KW is amazine... isnt it? what did you use for the coil windings to generate the power?
that my freind puts life into ol'mcgivers bones!
damn nice work tell the ol man from my ol man!
Cheers
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10KW is amazine... isnt it? what did you use for the coil windings to generate the power?
10kw is about 14hp, the generator appears to be a manufactured unit.
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As seen in the pic its mounted on a small frame trailer.I do have the engine out ,and in the works.Blocks at the machine shop getting blueprinted,had to be bored out to 3rd oversize.Bought my pistons from MYKE_w (of course)hes been a great deal of help and wisdom for me.My IP has 10mm pump and head with LDA assembly from a peugoet 505.I turned up the control cone,replaced intermediate gov. spring.I found the experience to be easier then i thought it would be(i kind of psyched myself out)The hardest part of the IP was mating the LDA to the NA bottom end.here are some more pics. :D
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel013.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel023.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel026.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel055-1.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel070.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel006-1.jpg)
I was going to use the gov spring from the peugeot,as it was stiffer,but i decided to go all the way with a piece of brass tubing cut to size.
more to come ....
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sorry pics are so big :oops: Im still working on the text to.Seems it wants to extend text all the way weird.Ill try some different posting techniques.Does anyone know how to avoid this?Can i resize bulk photos in photobucket?
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10KW is amazine... isnt it? what did you use for the coil windings to generate the power?
10kw is about 14hp, the generator appears to be a manufactured unit.
so you could put 5 of those generators hooked up to this engine and make 50 kw? full steam ahead!!!
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Dillinger1's Dad here. The generator design sat on a 4'x6' trailer. It took up so muchh space because I used the poly Jetta fuel tank as well; sitting that forward of the engine on the trailer. The transaxle output powered shorted axle that was welded to a jackshaft which had a 14" dual belt pulley. The other side of the belt drove a 4" pulley on the generator's shaft.
To control the generator's speed under all load conditions, I put an electronic speed governor on the throttle and used an inductive proximity sensor to measure the pulses from the ring gear teeth. I tried using the cruise control circuit but it would not respond fast enough to hold constant speed under any load changes.
To start the whole thing in motion I started the engine with the clutch pedal depressed. Used a motorcycle throttle to change rpm's as I shifted gears up to 4th gear. I then would bring the rpms close to 1800 and then throw the switch to activate the speed governor.
The only thing I made a mistake on was not welding up the diff. I thought I could get away with bolting down one side of the transaxle output; thus speeding up the other side. This only worked for a while until the differential heated up after a long day of heavy laods. I was going to weld up the Diff but ended up loosing interest.
All the generator parts are for sale now.
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Nice setup but I don't think I have ever seen a more rusty engine!
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Its mostly grease,I spent alot of time scrubbing it down.Took it down in steps,day by day,till i could see bare metal.Ill have the block back soon from the shop with 3rd oversize and blueprinted via magnaflux.Does anyone know why the text extends so far?What am i doing wrong here?
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there must be a way to control that thing with the governor... i'd say calibrate the pump to cut fueling @ around 1800-2000 rpm. then basically have two modes. idle, and 'load' whereas load is full fuel travel. rpm stays at 1800 because any sign of drop in rpm, more fuel is injected to hold that rpm... a very large amount of fuel can be injected to hold that rpm :twisted:
i like how this was designed... keeping the gearbox to increase efficiency :D
btw those pictures are somehow placed beside eachother extending the screen... very weird this thread is!
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there must be a way to control that thing with the governor... i'd say calibrate the pump to cut fueling @ around 1800-2000 rpm. then basically have two modes. idle, and 'load' whereas load is full fuel travel. rpm stays at 1800 because any sign of drop in rpm, more fuel is injected to hold that rpm... a very large amount of fuel can be injected to hold that rpm :twisted:
This is how it is done on a commercial unit. There are springs available for the VE pump to accomplish this. They are usually extensions spring with a fairly low rate and lots of coils. The constant speed springs replace the entire governor capsule.
i like how this was designed... keeping the gearbox to increase efficiency :D
How so? Every mesh of gears or belts consumes some power, best case would be direct drive.
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Photos of the generator before Dilinger1 got the engine.
http://s194.photobucket.com/albums/z44/ImSoAmish/VW%20Diesel%20Generator/
This unit is for sale less the engine. Generator was $500, governor was $300, trailer/otherstuff about another $300. Asking $650
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Heres some of what i did this week
(http://i249.photobucket.com/albums/gg206/2253benjamin/powder012.jpg)
before powder coat
(http://i249.photobucket.com/albums/gg206/2253benjamin/powder014.jpg)
after powdercoat
(http://i249.photobucket.com/albums/gg206/2253benjamin/powder008.jpg)
the pump all sealed up.I dropped off the pistons at the shop today.They said the magnaflux showed no cracks :D
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There is also this guy that made a generator. I do not know if he is on this forum. You have to clcik on the links in the paragraph to see the pictures, but pretty neat as all of the ideas are:
http://www.oldengine.org/members/jdunmyer/genset/
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Actually it's output is 13.4 hp, but I have thought of doing the same using a 3 phase motor.... imagine 3 phase power
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(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel004-2.jpg)
this is from a kit i bought as a whole specifically for t3,when i got it i didnt have the brass 4 way(didnt see it in box) :oops: which led to some confusion ,but everything is all good now.I still had to use some otherfittings to go to the turbo housing,so it wasnt really a full kit,but it also came with some gasket type fittings which i guess some t3s have instaed of the straight 12mm fitting.
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel005.jpg)
Hallman boost controller,i got this real cheap on ebay,ive seen them listed for quite abit. :D
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel003-2.jpg)
this is the t3 with some fittings i put together,i still have to retap the 1/4in pipe fitting to 12mm
(http://i249.photobucket.com/albums/gg206/2253benjamin/powder010-1.jpg)
And this bad boy will find its way in the trunk. :lol: :lol: :lol: :lol:
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Im picking up my block tommorrow ,and the fun will begin.Is this the proper way to do a build thread :oops: ,or should i wait and post it all at once?It seems like it would be more pleasant if it were togther.But then again im rather impatient. :D
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(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel003-3.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel002-1.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel004-3.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel005-1.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel006-2.jpg)
Cummins beige was the only logical color :D
The block is bored 40 over with .0015"wall clearance :D My guy said.001 was way to tight for me.He said i knew just enough to be dangerous. :twisted: hes right!
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SWEET! Looks yummy!
How much for the block service? I have a TDI block that needs done here soon!
Brendan
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The block is bored 40 over with .0015"wall clearance :D My guy said.001 was way to tight for me.He said i knew just enough to be dangerous. :twisted: hes right!
The spec is 0.0012" with a wear limit of 0.003", so both of you are as right as the other !
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At my shop it was $230 for a blueprinted 4 clyinder engine.It included all the measuring,magnaflux(for finding cracks),bake n blast(cleaning),and bore and hone. :D I always thought that they dipped the blocks.My guy said that thats so old school that no one even does it anymore. :oops: Im glad its all said and done.Very happy.
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heres some more progress.
I got the bottom end together today
and got it on the stand :D
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel011-1.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel013-1.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel014.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel015.jpg)
heres my intercooler from a saab 8)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel007-1.jpg)
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heres the head with welded bosses(cracked)as well as new seals. :P
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel007-2.jpg)
the head on the block
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel008.jpg)
manifolds on,which by the way was a pain.I had a stud that was corroded and gave me trouble.I also used a ALH intake that i chopped down :)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel013-2.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel012-1.jpg)
I think im gonna putn it in a 4-runner! :) I dont know i cjange my mind seems i would get more use out of it.sorry guys!
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel014-1.jpg)
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How come there is no injectors in your head? :P
oh wait i know why! :roll:
almost done!
Duane
hey is that a automatic tranny i see in one of thos pics.?
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ha ha thats funny!! :D :D Duane what do you think about start up without a radiator and coolant for like 15 seconds??
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i would prime the oil first! with a drill before i would do that! even stick needlenose vicegrips on the turbo so turbo don;t spin dry at first!
Duane
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So you are using an intake with the d-shaped ports on a 1.6?
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Hey is that waterport gasket on wrong?
Hard to tell but it looks a little like this:
(http://img509.imageshack.us/img509/9334/hydroblockgasketfuhw5.jpg)
Maybe you used one for the front waterneck
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Yep it HAS D-SHAPED PORTS theres just a little gasket in the airstream,and the sealing surface is a little thin around the top,but there is a seal.My water port casting is a little funny on one side so my gasket shows on the outside,The front is an o-ringed seal.I figure the d-port wouldnt be a problem since the air is pressurrized anyway
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well ive been dormant for awhile,but things are moving again.I had to wait to find a body for the motoir.I chose a 87 yota 4runner.She weighs in at 3000 lbs so its pretty much a vanagon.I wanted to do something a little more interesting.Plus were getting our bio system setup,so weve been busy.
(http://i249.photobucket.com/albums/gg206/2253benjamin/intake045.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/intake050.jpg)
heres what the toy flywheel will look like,and an adapter for the block.
(http://i249.photobucket.com/albums/gg206/2253benjamin/DSCN0438Medium.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/AdapterMedium2.jpg)
this is not my design.It belongs to flash319 for yotatech.heres a pic of our pad for bio setup.we really went all out on this one should be fun.
(http://i249.photobucket.com/albums/gg206/2253benjamin/intake044.jpg)
http://www.yotatech.com/f162/vw-diesel-build-up-135203/?highlight=vw+diesel+swap
heres flash319 build up ive been following.
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Ive finally got it running,with a little help from you guys that is. :) Ive got some troubles though.I had to turn the fuel screw in about 4 turns to even get fuel to the lines,Ive tried to back it off,but it seems theres a fine line to where it will run and where it wont get fuel at all.I didnt compare the spill ports when i had it out.I have it timed to 1.05mm,and theres a 10mm plunger from a peug.It will idle nice ,but it wont rev(poor response).It will run away when you hold the throttle at max for over 5 seconds,and wont come back down.I havent touched the gov. assembly(only used the peug inter. spring)Lda is still on peug. settings(I swapped it to a na pump)heres some pics anyway
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel015-1.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel016.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel004-7.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel007-4.jpg)(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel017.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel018.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel019.jpg)
we extracted more water through a drying process that blows air through hot oil,and seperates the water from it.
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I wish my thread wasnt so jacked up! :evil: Anyway im sorry for all those that have dial up.Dont let this hinder you from giving me advice. :) Anyways,does this sound like timing issue?
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my opinion is that your governor should resign :D
try with different settings of the throttle assembly, mine is on minimum, it idles without touching the idle screw. (I got tired of huge black clouds on the other settings)
it doesn't sound like timing issues, but you can forget about timing with the dial indicator, I guess it only works with stock parts, you have a sharper injection start now.
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hey Ben,
those pics. are so small except for 1! anyway you can post them bigger?
thanks Duane
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Does the peug pump head have a recessed hole where the 2 large springs rest?
Does the head you removed?
I'm not talking about the 2 little pencil side springs the 2 large ones that sit on a shaft on either side of the plunger.
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I dont think so.The springs where the same same shims and everything.Wouldnt the recess give them less preload if the springs are the same?the head i removed does not,its a vw 9mm head.It idles fine,sounds great.well you hit the accelerator it will only go to say maybe 1200rpm(no tach)When you hold down the accelerator for a while it will start to climb and run away.Are you guys thinking it almost has to be springs?is there anything else that will give this? ive not messed with the lda at all.Remember pump body is from an na.
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Ok ,i read some other posts and came up with the gov. assembly not being properly aligned with the collar plate.I forgot to scribe lines on the nut and lever for reassembly :oops: I know!Does anyone think this is culprit?If i use a picture of another pumps lever shaft/nut relation will this get me close?If the parts are identical then the adjustment should be right?
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If the main springs on the pump head are wrong it wont do much of anything correctly other than idle.
On the other hand if you have the throttle shaft keyed incorrectly that will cause the problem you are experiencing.
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I removed the accelerator lever,and it acted normally.first it fire,and i still had the full load way in!It fired and went for the moon. :D I backed that off to stock position,and removed the lever.I then gave it various settings of preload to determine my idle point.yah!So its behaving quite normally now.I still would like to know if the 10mm plunger is advancing the injection.I kknow it will be sharper,
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Ok ive still got some trouble.Ive got white smoke at idle with 1.05mm with 160bar "gtd"injectors.I think the injectors are slowing me down.I think i still need more advance! :shock:
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel001-7.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel007-5.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel008-3.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel005-3.jpg)
Ohh yahhh!check this out!! :D what could it be?hmmmmmm...
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel009-2.jpg)
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ohhhhhh Yah!!! :D :D :lol: :lol:
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel005-4.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel004-9.jpg)
2 1/2" down pipe home made with header wrap
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beatiful DP!
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that DP is identical to what im doing except im using 3'
Was that flex pipe expensive? are you concerned about it wearing badly?
I've been wondering if i'll burn through flex pipes like no tomorrow.
nice insulation. I'm going to do the same now that i see that
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the flex pipe is stainless (why would it burn?).I got it from summitracing for 37 dollars,they have weld on units to.
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(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel006-7.jpg)
I made a cage for the radiator,as it seems fragile with all the fins
mounted the intercooler
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel002-4.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel003-6.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel007-6.jpg)
my air intake is crazy!thats a dry AEM filter(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel012-4.jpg)
(http://[img]http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel009-3.jpg)http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel008-4.jpg[/IMG]
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel010-5.jpg)
this is the oil filter relocator i was able to use the stock sandwhich cooler.
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel013-5.jpg)
first fuel filter for the bio-diesel.It then goes to the stock filter.
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(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel004-11.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel001-9.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel002-5.jpg)
some down pipe magic for everyone.This was very tricky.It is very close to the cross member ,but ive got at least a 1/2"of room.as long as the hangers are in good shape it wont rattle.
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Oh man!this thing rips guys.At first i was scared because my fuel needed turned up(felt like the clutch slipping0but i did a 1/4 turn and sha-bam I only ran it up and down our short road.I was seeing 15psi and 1000f.Anyone who says this truck is to heavy needs a 10mm head assembly :D :D :D :D :D :DOh got rid of that ugly radiator cage too.
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wait till ya do some more tweekin and the water/meth injection!
Duane
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well this project is goin on almost 11 months now.had to scrap the 4runner as it had severe cancer on the backbone!I tell ya what thouh it went like stink!That motor moved that 4000+lb vehicle better then i ever would have thought.I scrapped the runner and bought a rust free pick-up for 500 buck w/blown motor.This truck is clean.Now im refabing everything i didnt like.
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel004-12.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/11c1f11483n53m33p98bob0f6cd80747a17.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel003-8.jpg)
look at that paint!oh ***.
(http://i249.photobucket.com/albums/gg206/2253benjamin/GetAttachmentaspx3.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/GetAttachmentaspx2.jpg)
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now im ready for the cab.I used valspar heavy equipment primer and paint.Its very thick,i could have thinned it 50%,but didnt 8) 8) I did the mount a little lower this time foor more firewall clearance.I went down enough to where i wouldnt have to modify my downpipe.even fired her up today to hear her run.If your curious,ive mounted the toy PS pump to the engine with a dual crank pulley,that i got from duane.blackboosted in da house!! :D :D the frame is absolutely perfect.
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel003-10.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel009-4.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel007-7.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel013-6.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel002-8.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel001-11.jpg)
water/meth anyone?ive got a 3.6gph @40psi and a 6gph nozzle.
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel015-2.jpg)
I ground my own pin from a altitude comp pin.I used a dremel grinding stone.It is concaved so the slope is more extreme then it looks!BOOYA! :D
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Im actually glad im doing it over.Everything is coming out nicer.I know what works and what doesnt now.This has been almost 11 months now!finish already.I know its not even a vw, what the hell.
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Sorry if I missed it, your IC in infront of the radiator and the radiator is closes to the engine ?
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intercooler is in front.The engine hardly heats up as is.
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(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel001-12.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel003-11.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel006-9.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel010-6.jpg)
got the cab on!!
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best 4 banger truck ever.
HEY! you're using a chopped ALH too!!! Did you know that i did the same?
=D
Did you port match the head to it?
I have an AAZ head with mine 8)
We have very similar intercoolers too :D
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Very impressive! Can't wait to see it finished!
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I used switched the alh manifold to a regular td intake.With the higher output i was worried about stange air turbulence hindering the intake stroke.I really dont think it did,but i was paranoid.The intercooler held 25psi so far.I know its gonna pop!
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you aren't using the ALH now?
the aaz head breathes 10% better than the 1.6td head so i don't think i have to worry about odd turbulance with the bigger manifold right? ( polished the head too)
Oh man, i hate that the sides are fibre glass!!! tig'ing your own sides would be hellish too. I'm not sure what im gonna do. I don't want to go above 25psi... i don't think. How much does a 4 door jetter weigh compared to that 4000lb 4runner you had? if your build makes that thing rocket will i have interesting results with mine on my 4dr?
I really have no idea what kind of improvement the engine work i've done(doing) will have/make compared to the stock 1.6td it was before i pulled it all apart. I'm just assuming im going to run into huge issues because i haven't spent very much money on it. I may end up just having to be really conservative on the pedal because i have a completely stock bottom end (Except for new rod bearings). The only thing i have going for me is that it's an MF block... (true TD block made for more boost and load i think? and oil squirter thingies. possibly a bigger oil pump too)
Am i digging my own grave with this?
I think i have a 9mm head and LDA? my plunger is a 9mm.
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If youve got a aaz head the manifold will work for you,as the 1.6 has round intake ports.Im gonna run the cooler anyways,Im sure ill settle down for smileage!
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oh i know it fits. I ported them to fit each other as best i could.
but my question is, what will the output of my stock pump powered aaz/1.6 t3 ... thing... be?
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stock fueling(plug wastegate) will get you maybe 60-70 ponies,but a little on the full load screw and youll be over 100 i bet!Just watch the smoke eddy!The intercooler will help cool it.This intercooler of ours is decent.I was laying a cloud down with 25psi,winding the gears out and i couldnt break 1400f(with a 10mm plunger).Its not gonna last though.ill abuse it so i can upgrade to a ebay 75$ special.About the intake.The aaz has "d"shaped ports, like a tdi does therefore it will bolt right on,without removing material from the head.The 1.6 has roound ports which will sit inside of the "d"shape,but there will be a ridge ,the air will hit(creating turbulence)when entering the combustion chamber.I like your enthusiasm eddy!! :)
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Shes a runner!
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel001-13.jpg)
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel005-6.jpg)
Me doing some extreme offroading out front in the ditch,Definetely gonna need a solid front.
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel003-12.jpg)
guages are going in the pillar.
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel004-13.jpg)
Had to cut the floor for clearance the v6 had a shorter span on the sticks.
(http://i249.photobucket.com/albums/gg206/2253benjamin/volkswagendiesel006-10.jpg)
badass smittybilt bumper with bed liner coating!!
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I think i need a metal HG though.I was floggin it to set the rings.It seem theres some coolant seeping out of the front by the oil drain for the hyd. lifters.I already went an extra 1/4"turn after warm up.Is it safe to go another 1/4?
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Looks good, is your cooling system pressurizing?
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I dont see bubbles (in the bottle)but i did have a leak that showed up unexpectedly(after a run).I tightened the hose clamp and it stopped.What about the coolant seepage?
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I dont remember how you have this set up.
Did you do the mls gasket? What head/ Block are you using?
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nope stock fiber gasket.86 hyd. na w/turbo components.
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Hmm, well are you positive it isn't/ wasn't just left over from a seeping hose?
Aside from retorquing the head I say just keep an eye on it to see if it continues.
Can ya get a pic of the leak?
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positive.the hose in question is the oil cooler hose,below the head.you can see it bubbling out and smell is strong.so you say1/4 torque, dan?I purchased a 1.9 metal hg.Should i torque the stock bolts again?
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What are the torqued to now?
When you did the first warm up/ torque was the cooling system presureized?
As in was the cap on?
Your suppose to leave the pressure cap off then torque, start and run to temp, shut it down, retorque (I think after cool down).
Any luck getting a pic of the offending area?
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fiber gasket install=
1. torque to spec
2. with coolant tank cap OFF, start engine and allow to come up to operating temp.
3. turn engine off and allow it to FULLY cool down
4. retorque
I HATE fiber HG's on these engines!! they are JUNK :evil: (if you want over stock boost numbers)
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fiber gasket install=
1. torque to spec
2. with coolant tank cap OFF, start engine and allow to come up to operating temp.
3. turn engine off and allow it to FULLY cool down
4. retorque
I HATE fiber HG's on these engines!! they are JUNK :evil: (if you want over stock boost numbers)
Did you warm up the first time w/o the cap and then torque ? If not, I'll bet you'll be taking that head off again for a new HG.
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fiber gasket install=
1. torque to spec
2. with coolant tank cap OFF, start engine and allow to come up to operating temp.
3. turn engine off and allow it to FULLY cool down
4. retorque
I HATE fiber HG's on these engines!! they are JUNK :evil: (if you want over stock boost numbers)
Did you warm up the first time w/o the cap and then torque ? If not, I'll bet you'll be taking that head off again for a new HG.
man have you not read my HG saga??
yes, your right I did not follow the procedure I posted and I blew my fiber HG on my test drive!!!!! :cry: :oops:
I have since sent my fiber gasket to Thailand and a place out there is going to make me a custom fit 1.6 multilayer steel headgasket...no AAZ MLS patching for me..this will be a 1.6 diesel specific gasket.
I hope to end any HG problems I had with this.
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fiber gasket install=
1. torque to spec
2. with coolant tank cap OFF, start engine and allow to come up to operating temp.
3. turn engine off and allow it to FULLY cool down
4. retorque
I HATE fiber HG's on these engines!! they are JUNK :evil: (if you want over stock boost numbers)
Did you warm up the first time w/o the cap and then torque ? If not, I'll bet you'll be taking that head off again for a new HG.
man have you not read my HG saga??
yes, your right I did not follow the procedure I posted and I blew my fiber HG on my test drive!!!!! :cry: :oops:
I have since sent my fiber gasket to Thailand and a place out there is going to make me a custom fit 1.6 multilayer steel headgasket...no AAZ MLS patching for me..this will be a 1.6 diesel specific gasket.
I hope to end any HG problems I had with this.
:-D No worries - I was asking dillenger1 if _he_ followed the process :-) I understood you had it down :-)
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fiber gasket install=
1. torque to spec
2. with coolant tank cap OFF, start engine and allow to come up to operating temp.
3. turn engine off and allow it to FULLY cool down
4. retorque
I HATE fiber HG's on these engines!! they are JUNK :evil: (if you want over stock boost numbers)
Did you warm up the first time w/o the cap and then torque ? If not, I'll bet you'll be taking that head off again for a new HG.
man have you not read my HG saga??
yes, your right I did not follow the procedure I posted and I blew my fiber HG on my test drive!!!!! :cry: :oops:
I have since sent my fiber gasket to Thailand and a place out there is going to make me a custom fit 1.6 multilayer steel headgasket...no AAZ MLS patching for me..this will be a 1.6 diesel specific gasket.
I hope to end any HG problems I had with this.
:-D No worries - I was asking dillenger1 if _he_ followed the process :-) I understood you had it down :-)
ooo ok...when you quoted me I thought you were asking me.. :lol:
yep it was my fault the HG blew...I thought I would not need the retorque so soon with head studs and all...oh-well I am happy with the end result...it forced me to get a better set-up. 8)
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i didnt let it fullt cool down and i bet the cap was on.Should i even try to go another 1/4 turn?
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Well at this point I guess you can't hurt anything really.
Go ahead and try, I'm said to say I think your going to be taking the head off again though.
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Head leak has either disapeared or was a spray from the cooler hose.everything is running great now after a few test runs.I was blowing return lines,so i just installed new cloth line.I did run some bio through it when first started,so im hoping that was it,as the return line isnt any smaller then the gasser return line(which doesnt matter i guess)what size is the factory return?here are some videos.chow! :D
http://www.youtube.com/my_videos#
http://www.youtube.com/my_videos#
happy new year videos guys.