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Engine Specific Info and Questions => IDI Engine => Topic started by: Alleslowbuged on February 05, 2008, 02:22:59 pm
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Hi,
my name is clemens and i am from Germany.
First of all, it is very nice to see american guys to work with old german engineered Turbo Diesel (IDI) stuff, mainly in that crasy professional way i see here.
But back to me and my car,
i have a VW Golf Mk1 from 1981 since nearly 3 Years with the origional 1.6 TD engine called CY. Additionally to modification on the car i change a little bit on the engine setup to increase the horse power.
That the parts setup:
stock air intake filter
stock garret turbo
huge intercooler (600x300x78mm), is the biggest what can be mounted
in the front of a MK1.
stock cylinder head (not opend by me)
stock engine block and lower parts
Ø60mm exhaust pipe behind the down pipe with sport silencer from
Papmahl straigh from the eightees (in best condition)
Bosch DN0SD297 nozzles
The max. boost level i runned until now is around 1.2 bar (can be adjusted from the vehicle interior) with special cone and spring in the fuel pump (the tougher spring is for reduce the smoke). The diesel pump is
then fine adjusted for the injection rate and the starting output (0,88 bevor OT [Uper deadpoint?])
For cooling, i have add special cooling fan, 80° thermostat and a separate oil cooler (stock from the GTI). I have a Ø210 sinter metal clutch with a FF (old 020) gearbox.
I try to add the last dynorun, but wand to explain that there was a big mistake in the adjustment of the fuel pump cone, which lower the injection rate at full boost pressure, that occurs no power increasing by increase the boost level from 0.9 up to 1.2 bar.
Results: boring 100HP@ 3600rpm and 280Nm @ 3200rpm
(meassured with a G-Tech Pro) I have reduce the 1/4 mile time from 18,06s with dynorun setup down to 16,33s with actual setup.
So that is the status quo, the car is sign off and waiting for the swap to a modificate 1.9 AAZ engine i will build up in the next month.
Power in kW
(http://img90.imageshack.us/img90/8803/leistungsdiagrammiz2.jpg)
(http://imageshack.us)
Torque in Nm
(http://img530.imageshack.us/img530/4987/drehmomentdc7.th.jpg) (http://img530.imageshack.us/my.php?image=drehmomentdc7.jpg)
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On the dyno run plot it is good to see, that there is not enough fuel above 4000 rpm as mention above.
Here are some more pictures for anybody who is interessed:
the original dynorun plot:
[(http://img507.imageshack.us/img507/194/leistungsdiagramm12barvo0.jpg) (http://imageshack.us)]
pictures, how i have buy it after ten years of down time:
(http://img507.imageshack.us/img507/8992/bc1bwq9.jpg) (http://imageshack.us)
(http://img210.imageshack.us/img210/2548/8a1bmr8.jpg) (http://imageshack.us)
(http://img210.imageshack.us/img210/144/631bpn0.jpg) (http://imageshack.us)
here the first intercooler (from a Opel Corsa 1.7 TD)
(http://img204.imageshack.us/img204/4936/motorraumkomplta7.jpg) (http://imageshack.us)
the second intercooler (from a Mercedes Sprinter)
(http://img529.imageshack.us/img529/5/erstereinbaued6.jpg) (http://imageshack.us)
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And here some actual picture:
front view
(http://img110.imageshack.us/img110/9241/p1010368gz4.jpg) (http://imageshack.us)
new instrument
(http://img502.imageshack.us/img502/7392/p1010372wr5.jpg) (http://imageshack.us)
for me clean engine by with new spal cooling fan
(http://img528.imageshack.us/img528/7593/p1010369cg3.jpg) (http://imageshack.us)
engine bay picture 2
(http://img409.imageshack.us/img409/1674/p1010370ot9.jpg) (http://imageshack.us)
intercooler preparing for painting
(http://img249.imageshack.us/img249/651/p1010276un8.jpg) (http://imageshack.us)
black painted
(http://img504.imageshack.us/img504/2218/p1010279yi0.jpg) (http://imageshack.us)
new Ø256er brake
(http://img162.imageshack.us/img162/9737/p1010278ad2.jpg) (http://imageshack.us)
changed mounting of the old cooler fan motor
(http://img299.imageshack.us/img299/8633/p1010319xf5.jpg) (http://imageshack.us)
mounting for the intercooler
(http://img299.imageshack.us/img299/5884/p1010310ot4.jpg) (http://imageshack.us)
intercooler mounted with water cooler
(http://img517.imageshack.us/img517/7304/llkxz8.jpg) (http://imageshack.us)
change design of radiator grill (total)
(http://img530.imageshack.us/img530/645/frontkv2.jpg) (http://imageshack.us)
change design of radiator grill (detail)
(http://img47.imageshack.us/img47/7370/p1010314me1.jpg) (http://imageshack.us)
and i'am at 1:30 in the night with a dirty bonnet after much of work in a very cold garage P.S. I'am not wilson from Tool Time:D
(http://img47.imageshack.us/img47/3560/p1010320yi9.jpg) (http://imageshack.us)
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Nice car :D
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Damn sweet MK1!
'Whoosh Tish' of a BOV?
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Hi,
Wolfsbur, sorry but i don't know what "'Whoosh Tish' of a BOV?" means.
As i mention bevor, i am planning to do a lot of modifications in the next time. Main is the swap to the AAZ base for increasing the cylinder capacity up to 1.9 ltr.
As Fuel pump i will modificat my stock AAZ pump with parts from a VP37 pump from a 1.9 TDI called AFN with a Ø10mm plunger and 3.7mm stroke disk, beacause i will run max speed up to 6000rpm i will also modificate the speed/startin output adjuster, for more adjusting range.
I think the original adjusting range is only for max speed of approx 5400 rpm, will mean 24° crank (increase to 30° crank)
Also i will change the manuel boost controller to a electronic HKS EVC II and install my water/methanol injection. In the moment i have install the water/methanol injection in my BMW E28 524TD after the intercoller, regarding to the manufactor refernce, but be not sure if that had be the cause for two head gasket failures. So i will install it in the Golf Mk1 bevor the intercoller and only use for boost levels above 1.5 bar.
I search for a impac momentum manifold, a 2.5" downpipe and perhaps for a nice inlet manifold, like that one from Passengers Diesel. So if anybody have these nice think for sell, i would be happy to get it offered or to get i tip, where i can get these parts.
Best regards, Alleslowbuged
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nice wip, I love the german styles...
Good luck
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Hello,
some new part has arived, so i get my new cluth, is for the 02a tranny.
Means it is Ø228mm, clutch blade has torsion spring and 8x sintered metal pad, pressure plate is a reinforced sachs.
I also ordered special tranny fastener, for mount the 02a tranny in a MK1, from a guy from the mk1 forum (golf1.info), which are also needed to use a mechanical clutch cable.
The clutch should be able to handle 500Nm, so no problem for my "little" diesel engine. Here is a picture from the clutch, i am still waiting for the fastener.
[(http://img337.imageshack.us/img337/410/kupplungax0.jpg) (http://imageshack.us)]
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:shock: that windshield washer reservoir would last me like 2 years, that's nuts
Very nice looking car
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Guess you can't have too much intercooler, eh?
Welcome to the board! If you haven't found out already, many of the maniacs on this board are running 2.0 bar boost or more. What's stopping you? :-)
-David
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Hi,
you are right, intercooler can't be big enough.
i have get my mk1 out of road, a few weeks bevore, because i have buy my 1.9 AAZ engine and wand to swap. Bevore that i allways wand to run my car also for everyday life and so i try to leave it fail safe.
Also pure boost don't bring you power without more fuel. As i describe bevore i had run the stock mk1 fuel pump first and then a change to a stock mk2 fuel pump, with housing firm idle speed adjustment. But in both case with very small and soft hub disk and and Ø9mm plunger. Short before i get the mk1 in my garage, i installed the better boost pin and stiffer spring for it.
But anyhow with that fuel pump setup, in my mind it makes no sence to increase the boost level up to 2bar, because it is very difficult to become fast enough, the needed fuel amount, to use all the air. And if you are not fast enough, you will grill your turbo without much more power, because a big amount of the fuel will burn, when the piston is short before botton dead center and also later.
I'am not sure if i have write that bevore, but i have a VP37 Pump from a MK3 TDI (AFN) (3,1mm hub disk, and Ø10mm plunger) here and will use that high pressure parts in my old IDI Pump housing. Also i planed to modify some more parts, to get max. spped of 6000rpm.
I will use this modificate pump first in my still installed 1.6 engine for testing and first adjustmend, that i not have to start my rebuilt 1.9 engine, while beeing not sure if the fuel pump will work. When the 1.6 engine will have that pump installed, i will increase fuel and boost level so long, until the first part will give up (headgasked, tranny) or my stock mk1 turbo is at his end.
Keep you informed :shock:
So, i hope you can understand my poor english
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Nicely done :D
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Hello,
even we have winter here since a week, i have my mk1 on the street again for 5 days, for bring it in my garage. I have done some fine work mainly on the cooling system, because one hose had a leackage, but now everything is fixed.
Before i start to ride with the car, i have tried to get more fuel out of the pump, but did not work so far. Anyhow i also increase the boost level after reading all this amazin boost levels here in the forum.
I have run with max. 1.4 bar, but did not get much more power because fuel amount at higher rpm's is too low. I can see in the driving mirror how the smoke decrease with increasing the engine speed. Even with 1.4 bar boost instead of 1.0 before, i did not more power. I have read somewhere, that by increasing the idle fuel amount, the max. speed is automatic decrease due to the design of the governor.
Here are some g-tech pics, the black one is with 1.0 bar the red one is with 1.4 bar. The poor 1/4 mile time with 1.4 bar also regards to bad shifting from thrid to fourth gear.
[/img](http://img237.imageshack.us/img237/4448/golfgtd114barsw1.jpg) (http://imageshack.us)(http://)(http://img20.imageshack.us/img20/3627/golfgtd114barrpmpv3.jpg) (http://imageshack.us)(http://)(http://img367.imageshack.us/img367/2917/golfgtd114barpowerrpmxq6.jpg) (http://imageshack.us)(http://)(http://img367.imageshack.us/img367/8294/golfgtd114barpowertouqrcq5.jpg) (http://imageshack.us)(http://Best Regards)
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Hi,
unfortunately i have to scrapping this car, because the rear axis support was to worse. Anyhow, i have a new project it is also a mk1 and should be a used as race car (if it will ever run sometime).
In the moment i am collecting parts and be very impressed from the finisch input here on the board. I will start with my old 1.6 TD, but will change the trany to a 02a type (ASD or CTN). Also i will use a special MLS headgasket (same like 53willy) with additional steam holes like the aaz. Turbo will be stock at the beginnig, but with a custom intake, so perhaps i have to turn the turbo.
Here are some pictures from the new project, they are from may but it looks nearly teh same today. My actual probelm is the coupling flywheel, i have lightned it (say EVO II), but it has still mechanical contact, so i have to lightned it more (say EVOIII), so that the axial backface is on the same level on the outer and inner diameter.
http://s702.photobucket.com/albums/ww24/euro-styler/
(http://i702.photobucket.com/albums/ww24/euro-styler/1790_1.jpg)
Best Regards
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Wow. Very nice and clean. Would love to have a perfect slate like that to start with. Roll cage would have to come out though. Keep us posted :D
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First of all, it is very nice to see american guys to work with old german engineered Turbo Diesel (IDI) stuff, mainly in that crasy professional way i see here.
And Canadians! we may be few in numbers but we count too! :P
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Hi,
sure also the candian and the scandinavian and all other amazing guys here you bild up crazy IDI engines.
Best Regards
Clemens
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Don't suppose you remember where or who the clutch was from?
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Hi,
i get my coupling from ebay.de, it was pretty new, but from a private who could not use it. But just before i found it on ebay, i was in conatct whith dss (diesel speed shop), here is the link, with a competitive price:
http://www.diesel-speed-shop.com/index_fichiers/Page1829.htm
I have got my mls custom head gaskets for my 1.6 TD (mechanical) from gasket-to-go today, here some picture:
http://s702.photobucket.com/albums/ww24/euro-styler/?action=view¤t=P1010006.jpg
(http://i702.photobucket.com/albums/ww24/euro-styler/p1010001.jpg)
Best Regards
Clemens
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Hi,
so my 500Nm clutch is installed and the 02a (ASD) tranny in bolted on.
http://s702.photobucket.com/albums/ww24/euro-styler/?action=view¤t=1-6-td-mit-02a-Getriebe.jpg
(http://i702.photobucket.com/albums/ww24/euro-styler/1-6-td-mit-02a-Getriebe.jpg)
greets from germany
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Dear all,
i have had a week vacation, so i could make some proceed on my diesel race car.
The main time i have worked on the suspension and brake sytem.
On the front axis, i have get my adjustable (camber and caster) strut bearing and could assemble the complette axis incl. the brake. I have also installed PU bearing for the control arm.
(http://i702.photobucket.com/albums/ww24/euro-styler/Domlager_TK-oben.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Domlager_TK-unten.jpg)
I hat some issue to install the strut bearings on the suspension, but could fix that.
(http://i702.photobucket.com/albums/ww24/euro-styler/Federbein_vorne_1.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Federbein_vorne_2.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Federbein_vorne_4.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Federbein_vorne_6.jpg)
I have pull all parts to max. negative camber, thats why it looks so extrem.
(http://i702.photobucket.com/albums/ww24/euro-styler/Vorderachse_1.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Vorderachse_2.jpg)
Knowing, that this will bring no proceed, i wand to know how it looks with my rims. The rims are 14" and fit radial with the brake, but for axial fitting, i have to use 20mm plates (picture with 23mm plates).
(http://i702.photobucket.com/albums/ww24/euro-styler/Vorderachse_4.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Vorderachse_5.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Vorderachse_6.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Vorderachse_7.jpg)
On the rear axis, i have mashined wheel hubs from the stock brake drum, so that i could use every VA brake disk. Actual status is to manufacture a brake mounting adapter. I have also installe negative camber plates and a adapter plate, which bring the rear axis down, if the car is lowered.
(http://i702.photobucket.com/albums/ww24/euro-styler/Hinterachse_2.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Hinterachse_3.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Hinterachse_4.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Hinterachse_5.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Hinterachse_6.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Hinterachse_8.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Hinterachse_10.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Hinterachse_11.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Hinterachse_12.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Hinterachse_13.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Hinterachse_15.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Hinterachse_16.jpg)
Here is a link to all pics:
http://s702.photobucket.com/albums/ww24/euro-styler/?action=view¤t=Hinterachse_16.jpg
Best Regards,
Alleslowbuged, who just bought a S2B Schwitzer turbo charger for his 1987, 524 TD E28 BMW.
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Very nice:D interesting reading keep up the good work
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Looking really good! Very nice project!!
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Dear all,
first thanks for your nice comments, it is good to hear, that my own *** is also interessting for other guys.
I good make some process on the weekend, my fia approved seat comes on friday i could nearly finish to install it.
On the other side i have also received the cast exhaust manifold from 53 willys and had began to work on my custom intake manifold. The good new is, that there will be no collision between the intake- (from VW LT 6 cylinder NA) and the exhaust manifold and the tubo. The bad new is, that the MK1 stock turbo (some kind of garrett) has lots of internal cracks in the housing.
I have compared them with my smaller BMW (524 TD, 2,5ltr.) stock turbo (K24) and have to say, that both are very similar from housing and compressor and turbine wheel diameter, although the bmw has 50% more swept volume. I will come back with some new pictures.
(http://i702.photobucket.com/albums/ww24/euro-styler/BR6dmwWkKGrHgoH-DwEjlLlfO9BKd1bDsf_.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/632f_1.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/6a08_1.jpg)
Best Regards
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Nice work, good to see another MKI GTD here in Germany.
Where in Germany are you?
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Hi,
i am in Bielefeld, if you look for other MK1 driver or information:
www.golf1.info
Best Regards
Clemens
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Dear all,
here some new pics, from the installed seat and the fitted intake and exhaust manifold. The intake manifold is based on a 2.4 NA LT28 6 cylinder intake.
(http://i702.photobucket.com/albums/ww24/euro-styler/P1010020.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/P1010021.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/P1010022.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/P1010023.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/P1010024.jpg)
Best Regards
Alleslowbuged
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Dear all,
i have remount the engine and after pulling the head, i has to realize, that there was water in cylinder 2, wich caused corrosion.
Anyhow, after two weeks with oil and diesel, i could remove the corrosion with very fine sandpaper and WD40.
I have also cleand the sealing face of the engine block.
Next step will be to fit the shifting device.
Best Regards
Clemens
(http://i702.photobucket.com/albums/ww24/euro-styler/P1010052.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/P1010053.jpg)
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First of all, it is very nice to see american guys to work with old german engineered Turbo Diesel (IDI) stuff, mainly in that crasy professional way i see here.
And Canadians! we may be few in numbers but we count too! :P
It looks to me like there are more of you here than anyother type, do you all know eachother ;D
I remember back in the 60's when I was in the Navy an older lady saw me in my uniform one day and said, "My Grandson is in the Navy too, do you know him? ??? ;D
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Hello,
not much process in the last weeks. In the moment i am workin on the gear shiftbox and the
conection to the gearbox. Also i have mount a hydraulic (fly off) rear brake, but i am not happy
with the position and i think i will change it again.
My cylinder head is a company for port ant polish, i shedule to get it back at the beginning of next
week. I will add some picture when it arrives here.
(http://i702.photobucket.com/albums/ww24/euro-styler/P1010028.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/P1010029.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/P1010030.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/P1010031.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/P1010032.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/p1010033.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/levervalve-LRG.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/vxcz.jpg)
Best Regards
Alleslowbuged
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Dear all,
i get my ported and polish 1.6 mechanical head back, also the valve seats has been mashined to a slightly bigger diameter
I will use the LT28 intake manifold, modified to a dual plenum intake and also with ported chamber (same as head intake ports).
Here is a picture, with pipe direction to the wrong side (non driver side):
(http://img684.imageshack.us/i/disescheie002.jpg[IMG]The exhaust will be a the log type one shown on last post, with will be also adjusted to the head exhaust port side.Here are some pics, i have add a picture, with new size gasket on a stock head, to see the different.[IMG]http://i702.photobucket.com/albums/ww24/euro-styler/DSC01905.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC01901.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC01900.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC01899.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC01897.jpg)
Here the new gaskets:
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC01904.jpg)
I have also take my 1.6mm MLS gasket to mark the additionally "steam holes", then
i have drilled 4mm holes.
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC01907.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC01909.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC01908.jpg)
Best Regards
Clemens
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Fantastic port job.
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Nice build. What happened to the 1.9 plans?
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Hello,
i have just the title of this thread, as also the car the change from my old mk1 street car
(which should get a 1.9td swap) to the yellow race mk1 with 1.6 td engine.
As compensation for the other mk1, i have bought a mk2 with aaz engine which is actual
broke down. Here is the link: http://www.vwdiesel.net/forum/index.php?topic=24407.msg186924#msg186924 (http://www.vwdiesel.net/forum/index.php?topic=24407.msg186924#msg186924)
Best Regards
Alleslowbuged
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Hi,
i did not have wrote here for long time and to be honest i did not have make big progress, but it is still an actual (waiting) project.
here is a picture, what happens if stupid person (the same who has made the hopefully good port job) don't listen and make what
he wants, after years of waiting. The pipe-part is cut out again, but the manifold is still waiting for new effort.
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC02037.jpg)
Next step was to make a stand-alone outer part of the shaft drives. The parts a needed to pre-stress the front wheel bearings,
otherwise the bearings will be scrap if the have to carry the full weigth of engine and chassi.
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC02387.jpg)
So after this was done, i could put the whole front axis together and put the car on its own wheels (first since it is mine):
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC02393.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC02394.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC02395.jpg)
Whith the 14" rims it is pretty tight with the brakes:
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC02398.jpg)
Next was the brakes itself, i have bought a set of "stahlfelx" (i don't know the english word) flexible brake hoses and
will install them inside the car:
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC02388.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC02401.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC02402.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC02403.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC02404.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC02405.jpg)
The actual status is, that the two hoses to the rear brakes are in the cabin and i have drill two additional holes in the back domes
to bring them out to the brake again.
I will go ahead with special Ø256mm rear brake disks and stock (MKII) Ø38mm brake caliper. Here are some pics of the installed
disks and adapter together with the new rear shock damper:
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC00053.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC00052.jpg)
As the 14" rims do not fit with the rear brake, i put the car on a set of 15" rims:
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC00058.jpg)
I have bought a new honed (first oversize) SB engine block with new pistons will go ahead with that.
To use my mechanical cylinderhead i still have to close the additional oil return hole. But more unlikely
is, that the guy i bought the engine from was a 100% specialist, who put all bearing covers together
in a box and used for each cylinder the one which was first to catch. After that he was wondering, why
the engine could not rotate, but he tried to rotate it, which results in some unpretty marks in the new pistons.
Anyhow, i have measured all parts, find their correct place and came to the conclusion that everything can
still be used.
Here is a scratch at the upper part of the pistons:
(http://i702.photobucket.com/albums/ww24/euro-styler/1_6er%20Hydro-Motor__RA/DSC02412.jpg)
and to pistons with scratch at the lower part:
(http://i702.photobucket.com/albums/ww24/euro-styler/1_6er%20Hydro-Motor__RA/DSC02416.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/1_6er%20Hydro-Motor__RA/DSC02418.jpg)
I have shown the pistons a proffesionell engine rebuild shop and they meaned that it is not that bad, so i have
regrinded the spots.
Today i have swapped the stock conn-rods to a set of china H-beam con-rods:
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC00351.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC00352.jpg)
Best Regards
Alleslowbuged
Last step was today t
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I love pictures. :)
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Wow, dude that is such a cool lookin' car!!!!
Any idea what the scratches in the piston are from?
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Nice shift linkage. The same as I use on my 02J but with an 02A tower.
Nice little car.
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Wow, dude that is such a cool lookin' car!!!!
Any idea what the scratches in the piston are from?
Neither of those sets of marks look like they were created during engine operation. Down at the skirt looks like a bench clamping issue.
Top gouge is one way only and probably comes from someone slipping out of the ring groove whilst cleaning with a piece of ring...
No to-ing and fro-ing affirms this 8)
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Hi,
@Mark
you properly right, the engine rebuilder says the same. Regarding the upper scratch he also means that as long as the ring is totally free to move,
this would be no issue, as dark black smoke will close the extra space from the scratch rather quick.
Greets
Alleslowbuged
P.S.
What means to-ing and fro-ing?
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Hi,
@Mark
you properly right, the engine rebuilder says the same. Regarding the upper scratch he also means that as long as the ring is totally free to move,
this would be no issue, as dark black smoke will close the extra space from the scratch rather quick.
Greets
Alleslowbuged
P.S.
What means to-ing and fro-ing?
Chuckle brothers would say "to me, to you".
Perhaps backwards and forwards, or shuffling, 'working' it's way down, up and down, 'in and out'... ;D
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ccc....puzzle again.
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what kind an intake manifold have you used?
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Hi,
as short update, i could finish the rear brakes today:
left:
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC00451.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC00452.jpg)
right:
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC00453.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/DSC00454.jpg)
So at least i have to fill it up (brake system) und deaerate it.
Best Regards
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Nice shift linkage. The same as I use on my 02J but with an 02A tower.
Nice little car.
Yeah, I've seen that setup before. You got it from Claus von Essen Chassis Works & Golf 1 Special Parts didn't you?
http://www.clausvonessen.de/pi38/pd648.html (http://www.clausvonessen.de/pi38/pd648.html)
Totally gonna get that setup myself. What's the diff-mounted relay lever off of, or is that in the kit too?
Finally nice to see a working pic of it on a car, and the Corrado/Eurovan clutch actuator; this looks to be a seriosly good car. 8)
Thanks for the progress pictures!
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so your ports are actually larger than just port matched?
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Hi,
yes they are bigger than port match, you cut see the special gaskets for intake and exhaust mainfold on the last page.
Yesterday i bring the engine block to a machine shop, they press a tapert alu plug in the additionally oild drain for the hydo
cylinderheads and plane the sealing face by 0.08 mm for ensure best possible sealing. The plug is necessary because i will
use a mechanical cylinder head.
So now i can start to rebuild the botton end of the engine and than measure the gap betwenn the piston and the sealing face
for calculate how much will be the gap bewteen the valve and piston in TDC. In regard to my new experience with my 1.9 AAZ
engine i will machine the cylinderhead once more and will put the valve position deeper in the head for enable the setup for
higher stroke camshaft.
@CrazyAndy
Yes the gear linkage is from Claus von Essen, the relay lever is from a 020 gear and not included in the kit.
Best Regards
Alleslowbuged
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I had the same clutch disk as you do and it unfortunately came apart and grenaded.
I hope you have a longer time with it than i did. Mine lasted less than a year...
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@CrazyAndy
Yes the gear linkage is from Claus von Essen, the relay lever is from a 020 gear and not included in the kit.
Best Regards
Alleslowbuged
Thank you for the information! It is good to know that I sould find that part.
Good luck with the sealing and port releifing of your engine and cylinder head, respectively. Don't forget to take many photos.