VWDiesel.net The IDI, TDI, and mTDI source.
General Information => General => Topic started by: zukgod1 on February 09, 2008, 09:03:32 pm
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http://www.dubnetworks.net/showthread.php?p=18101#post18101
For anyone that's interested.
Made some progress today. The new engine is all but assembled I just need to clean up the intake manifold, block off the factory pop off valve and get the P/S and A/C pump mounted up.
If anyone has some suggestions please feel free to post up as I go.
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Killer wheels man, Im totaly tuned into this build! Nice work btw
Keep her in motion
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everything looks very clean! good luck!
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Dang Dan! those rims are bad ass! i like those! hey do you need a upper radiator hose for your MK2? i have one thats new was sent as a wrong part to me from parts place! cost me like 44bucks and i don't have a MK2 and i don't have the recipt anymore to return it!
let me know?
thanks Duane
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Dang Dan! those rims are bad ass! i like those! hey do you need a upper radiator hose for your MK2? i have one thats new was sent as a wrong part to me from parts place! cost me like 44bucks and i don't have a MK2 and i don't have the recipt anymore to return it!
let me know?
thanks Duane
Crap Duane I JUST bought all my hoses from myke_w!!!!!!
I may take it anyway ;)
Thanks for the comments guys, had allot going on over the last few weeks that has really slowed me down. Lost a cousin then had to run to Seattle and now I've been sick for 7 days tomorrow..
I spent some time out there yesterday but I was working on blkboostedtruck's pump ;)
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Getting closer to driving it :)
http://www.dubnetworks.net/showthread.php?t=1748
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Nice! What size are the wheels?
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Killer shot there... I love how the rims look in front of those shiny re-built caliper....
It all looks good togethor, Im also wondering what size the wheels are!
Your doing well, really well! Motor looks so nice an clean...wowo
keep going!
Will you sell those OEM vw wheels? What are they from?
Lastly Im really wondering which suspension you put in vs. rim sie because Im sure I have the same suspension but mines not sitting like that at all...
What's your secret?
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Killer shot there... I love how the rims look in front of those shiny re-built caliper....
It all looks good togethor, Im also wondering what size the wheels are!
Your doing well, really well! Motor looks so nice an clean...wowo
keep going!
Will you sell those OEM vw wheels? What are they from?
Lastly Im really wondering which suspension you put in vs. rim sie because Im sure I have the same suspension but mines not sitting like that at all...
What's your secret?
The Wheels are 16" Keskin's. 7.5 in the front and 9" in the rear.
I suspect I can sell the OEM wheel as they wont clear the brakes now.
They are off my 96 Jetta, tires are dang near new as well.
The suspension consists of KYB GR2 struts and Neuspeed Soft Sport Springs, specs say they only lower it .5" so I cut a coil off. not looking for a ground scraper but I do want it lower than a .5" drop.
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This baby is up and running.
I have a few issues to address though.
The delivery valve I installed seem to be to big, I'm getting a really lopey idle.
I dont have any power going to my cooling fan relay.
Then the worst part, my clutch is messed up.
Feels like its worn out (new clutch disk) I have no peddle movement to speak of. I have about 2" of peddle movement off the floor and as a result I cant get it in 1st when it's running. It doesnt slip at all under heavy accell though.
Just feels like the push rod is to short and isnt sticking out the input shaft far enough, I wonder if I used the wrong plate that pushes on the pressure plate????
Anyway, it's about done.
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you talking about that 10mm i sent you?
Duane
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you talking about that 10mm i sent you?
Duane
No, under where the injection lines attach to the IP is where I'm referring to.
There are valves under there called "Delivery Valves". The ones I uses where from a 2.4ltr Toyota pump and the groves where much larger so I figured they would allow the fuel from the 10mm head through easier.
Well it does but a tad to much.
Ever seen a 1.6 smoke while idling?
I'll see if I can get a vid of it tomorrow. Lopey idle and black puffs of smoke with each lope.
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ahh ok !a vid. be great like to see that!
Duane
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http://www.youtube.com/watch?v=cUhz7aWZ35E
Here is a short vid.
The engine was cold so it wasn't smoking like it does when warm.
It will blow black smoke rings when it's warm.
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Getting closer to done.
(http://www.dubnetworks.net/dubhost/d/3462-2/IMG00063.jpg)
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I saw in your other thread that you've got an FF trans. As far as I know, nearly all of the FF code transmission do not have the bosses for the MK II rear trans mount. It is possible that there are late FF transmissions out there that have the bosses, but I've yet to see one. So, you may want ot do a side-by-side comparison to make sure it'll mount up. I had a nice FF that I was gonna put into a MK II: wouldn' happen. You may have to go ACH. With the power your motor will put out, you should be OK. The only variable will be the bigger rims.
Let us know how it goes.
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I don't have the old one out yet but at first glance I don't see anything different between the two. Only 3 mounts total and the one on the trans is in the same place on both transmissions.
Is the FF trans a weaker trans or are you refering to the gear ratio on the bigger wheel comment?
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We'll, I'm looking at 2 FF transmissions here in my garage. Neither one has the bosses for the rear aluminum mount for a MK II. The FF was originally a MK 1 trans. It was popular on the early models (1978-1982). As far as I know, only the late (1983-1984) transmissions had the bosses (the thickened tubes on the side of the diff casing), to accept the later MK 2 style rear mount. If I'm not mistaken, only the 9A, 2H, and 4K transmission had those bosses for the mounts: basically, only the late MK 1 transmissions with limited slip had them. I had to find out the hard way: by assuming that the FF would fit into a MK 2. I ended up having to buy an ACN. It was a bad match for my 1991 Jetta, because I had a 1.6NA pumping out a mere 55 hp.
Anyway, the FF that I tired to put into my MK 2, and the ones I have in my garage, all lack the bosses on the diff housing to bolt up the mount. The MK1 used 3 studs on the pass side of the trans, the MK 2 uses 3 bolts on the pass side. The holes between the two models are offset by one hole. When looking at the FF in my garage, there is only 1 out of 3 of the bosses in place. This is not a matter of stregth, as much as it is about ease of mounting. You could mount the FF in the car, but you'd have to weld on some bosses and drill them out, or transfer the guts to a MK II casing.
So,either way, I doubt that your trans has the bosses for the MK 2 rear mount. It's possible I guess, if you happen to have found a late MK1 FF code that is actually ready to go.
As far as the rims, I was suggesting that if you can't get the FF to go in, you might want/have to buy one of the ubiquitous ACN (typo in original message), ASF, or ACL that came on about 80-90% of all other MK 2 gassers. All of these transmissions have 3.67 gears, but do have a .75 5th. I'd be reticent (having tried one) to put any of these transmissions on a stock 1.6NA, since the final drive really kills the power band. But, since you'll probably be pushing a lot more HP than a 1.6NA, then you might be good (maybe even perfect), with a 3.67 FD
The only drawback I forsaw, was that you had some large, and presumably heavy, rims on the car. The greater rotational mass coupled with the larger diameter, requires greater torque to spin the wheels. So, the 3.67 may not be geared low enough to get you optimum performance at low speeds. At highway speeds, you'll get great fuel economy. But takeoffs might be sluggish. The only way to find out how it will perform is to get your car tuned the way you want it, and try out either trans (with a 3.94, 3.89, or 3.67) final drive.
Let us know how it goes.
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Well I will get the old one out tomorrow and compair the 2 to see what's up, I actually have 4 FF transmissions so I may be ok. I will report back once I get the old one out.
As far as the wheels go, I'm sure they are heavier but the overall dia is the same, the mass isn't a big geal with the power I have at the moment. Who knows this may take a couple swaps to get it right.
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I just got home so I grabbed a flashlight and went out looking.
You are correct sir!! :cry:
The FF I have sitting here doesn't have the bosses I need for the alum part of the rear mount.
The other 2 I have are FN's not FF's then there is another FF as well.
I'll have to look at them tomorrow. Other wise it's back to plan A which is to head to the salvage yard Saturday where I found a couple ACN's this week.
I guess if I was really ambitious I could swap the 5th gear... I would still have that damn 3.94 r&p though...
UNLESS!! I take the .71 5th and install it in a ACH trans, then I would have the 3.67 R&P and the .71 5th gear :twisted: 3100 rpm= 79 mph..
I sure appreciate the heads up, I would have been bummed way more if I had not discovered this until Sat.
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Hmm. A couple of thoughts.
If you already have an ACH trans (note, different from an ACN), why not just use that? It's got a 3.94 final drive and a .75 fifth gear. It's an original diesel trans (only came on diesels) and it's probably perfect for your car. Or are you talking about buying an ACN, and installing the .71 off your FF trans?
I wouldn't recommend swapping a .71 onto any trans, unless it already had a .75 5th gear on it already. The change between the two would be rather dramatic, especially when you're between about 50-65 MPH, which is where most people drive all the time.
As for the FN, it's got the same gears as the FF, and may in fact have the bosses, since it was used on later cars (up to 1983). You may look into that bit further before buying another trans.
Also, with the FF, if you're thinking of pulling the 5th gear, you'd better get the production date off the bottom. According to Scirocco gears page, the early (up to 1980) FF trans had a ..75 5th gear, and the later ones had a .71 5th gear. Hard to believe, but I had one of each. I tried each on my Rabbit, and I could tell a difference. Heres a link for a production date decoder:
http://www.4crawler.com/Diesel/VW_020_transmission.shtml
Good luck.
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Hmm. A couple of thoughts.
If you already have an ACH trans (note, different from an ACN), why not just use that? It's got a 3.94 final drive and a .75 fifth gear. It's an original diesel trans (only came on diesels) and it's probably perfect for your car. Or are you talking about buying an ACN, and installing the .71 off your FF trans?
I dont have either but can get at a salvage yard. I want the tallest gearing I can get for this car thus the 3.67 and .75 desired ratio found in the ACN.
If I install the .71 in anything it would be the ACN not the ACH.
I wouldn't recommend swapping a .71 onto any trans, unless it already had a .75 5th gear on it already. The change between the two would be rather dramatic, especially when you're between about 50-65 MPH, which is where most people drive all the time.
See above, installing in a ACN which has a .75 5th.
Also, with the FF, if you're thinking of pulling the 5th gear, you'd better get the production date off the bottom. According to Scirocco gears page, the early (up to 1980) FF trans had a ..75 5th gear, and the later ones had a .71 5th gear. Hard to believe, but I had one of each. I tried each on my Rabbit, and I could tell a difference. Heres a link for a production date decoder:
Yes I'm aware some of the FF's had the .75 instead of the .71 5th gear. And obviously I would count the teach before I installed it. Wouldn't make much sense to swap a .75 for a .75.
I'm going to check out the FN's I have access to and if one of them has the needed bosses than I will just use that trans, other wise I'll be heading to find an ACN Saturday.
Thanks again for the heads up.
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Fixed..
That's weird, I quoted everything backwards.....
Oh well I'll bet you can figure it out.
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Not that I doubted him but Quantum TD was correct.
The FF trans is missing the mount locations on the rear of the trans the FN coded transmissions are missing them as well.
I looks to me like it would be cake to make a plate to mount to the trans so the rear mount had a place to bolt to but as I'm not really sure of which FF trans I'm working with (.75 vs .71 5th gear) I'm not going to mess with it.
Saturday I'm heading to pick up an ACN coded trans.
BTW, that wasn't fun removing the trans. Not really hard but it's been YEARS sense I've removed one so it wasn't fun.
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I was able to locate and install an ACN today.
MUCH nicer, now instead of 66mph @ 3500rpm it's at 84mph same RPM.
Wonderful..!!
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Mr Diesel (from Dubnet) and I spent the morning pulling a trans out of a car @ the salvage yard then reinstalling it in my car at home.
Took it for a quick drive and the gear ratio was WAY better. Didn't get to drive on the freeway like I had planned as after a couple mile of back roads the damn block heater pushed out and the coolant proceeded to blow out the hole
Was able to baby it back home and decided that was enough fun for the day so I took Mr Diesel home and returned to my house.
Upon my return I decided to go ahead and get the car back in the air so I when I decided to start on the block heater issue it would already be in the air.
Well 5 min later I was back under it trying to figure out what I was going to do, I removed the block heater (new BTW) and headed out to the shed to figure it out.
compared my new one to one Mr Diesel had given me and they were identical. So I installed the used one and same problem, it wont tighten, removed it again and took a look at the new one once again. I tried a larger O Ring on the new one but no go so removed yet again. Then I took a look at the old one and compared the anchor to the new one and I'll be danged if the new one wasn't assembled incorrectly. Took it apart and reassembled the correct way then reinstalled and BAM! it tightened up.
So with that out of the way I decided to try to figure out why it was running warm so I removed the front of the car again and pulled the radiator out. It looks like it may be a tad plugged up so I'm going to figure out a way to back flush it then I'll install a Passat fan assy and see if that takes care of it. There is quite allot of dirt and debris in the fins so I'll take the rad and A/C condenser to the car wash and wash them out before I reinstall them.
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Couple more pics for fun.
Need to get the spoiler on the trunk, tinted windows, some kind of security system, and a spoiler for my roof rack. Oh ya, and get the knee bar installed and the Recaro's.
(http://www.dubnetworks.net/dubhost/d/3513-2/IMG00079_002.jpg)
(http://www.dubnetworks.net/dubhost/d/3516-2/IMG00080_002.jpg)
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Damn where's all your snow? I'm going to move in with you or Cody
Progress looks good
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lookin good man, perfect interior! Im down with the way you mounted the lcd....you got gps by chance? That's stock mk2 center consol area you fab'd it into? what size is the screen 7"?
Damn where's all your snow? I'm going to move in with you or Cody
Progress looks good
tyler, there not as lucky as we are having piles of snow dampening progression and their salvage yards covered! canada's white gold, just wait for the melt pffff
Damn nice progress forsure!
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lookin good man, perfect interior! Im down with the way you mounted the lcd....you got gps by chance? That's stock mk2 center consol area you fab'd it into? what size is the screen 7"?
That's a Pioneer AVIC-Z2, 30 gig HD, Navigation, XM, DVD, Blue-Tooth.
7" touch screen.. Paid more for that than the car.
Yes that is a OE console I modded to fit the head unit. I'm going to have to trim the knee bar so it will clear the back of the unit as well.
Then I'm thinking I'll get 2 more consoles and cut the face of one for a dummy face on this one so when I get out I can just slide it over the head unit making it look like a stock console with no radio at all then keep the other one for when the car goes away I'll have a good console to re install.
I'll get the front Recaro's in tonight probably, already installed the matching rear.
Thanks for the comments.
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Did some playing around last night.
(http://www.dubnetworks.net/dubhost/d/3618-2/IMG_0561.JPG)
(http://www.dubnetworks.net/dubhost/d/3612-2/IMG_0560.JPG)
Pulls good, and keeps it right @ 30psi where as to before I could hit 40psi under a hard pull.
I'm going to search for a better front bumper then spend more time trimming so it looks/fits better then I think I'll take some stretched metal and bend it the shape of the bumper then have it powder coated black.
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nice front mount, I really like how clean it looks up front
Is there a link to the place you bought the cooler from?
the progress on your rides coming along so nicly
keep it coming man, im anxous to see what your doing with the bumper...
but overall very nice build
what EGT are you seeing now/ there must have been a drimatic drop in temps from before and after install
good work and very exciting to read
props
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Thanks for the comments.
I didnt notice a dramatic drop in temps but it's better for sure. I can hold the peddle to the floor longer. Can still hit 1400deg on a good pull.
Normal cruising was about 900 deg @ 75 mph and 6-7 psi.
Now @ cruising it's 750-800 same speed and boost.
Defiantly has more power in the bottom end though.
Planning on stretched metal to replace the area I had to cut out and having it powder coated in black, bend the same shape as the area removed (I hope) and bolt it on. Still need to get the flares and side skirts on as well then get the black part of the bumper's painted.
Intercooler link http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1&item=250219901631&ssPageName=STRK:MEWN:IT&ih=015
And the piping kit I used, I added a 45 deg pipe, 2 90 deg silicone boots, a couple hump hoses and a few extra clamps also.
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1&item=250226585237&ssPageName=STRK:MEWN:IT&ih=015
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Figured this thread was SO old I would add an update.
I had long ago removed the 10mm pump and installed a fresh 9mm pump.
Well after a long internal debate I decided to build another 10mm pump.
I used one of my TD pumps i had and tore into it. It all looked good so I bead blasted the case and pressed in new bushings. 53willys reamed them to spec for me then I assembled it with a new AAZ cam and a 10mm pump.
Was able to get it all installed in a few hours and timing set to 1.07mm.
I had blkboostedtruck set my new injectors to 165bar thinking that when they settled in they would end up around 160bar or so.
Anyway, went for a drive to Sears and could smell diesel when I got out. I didn't even want to look so I didn't till I got home and sure enough the one cover you cant do anything with when it's o the damn car was leaking, cold start advance cover. So I removed the pump again and just replaced the cover. Re installed then set the timing the next morning yet again. I also set eh internal pressure to 40psi @ 1000rpm.
Runs butter smooth now all the way the RPM range. I also installed a very aggressive fuel pin. Damn thing will pass 30 psi now :twisted:
Time will tell but with the new pump and new injectors it's a entirely different car once again.
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Some recient pics.
(http://i176.photobucket.com/albums/w168/zukgod1/Picture015.jpg)
(http://i176.photobucket.com/albums/w168/zukgod1/Picture038.jpg)
(http://i176.photobucket.com/albums/w168/zukgod1/Picture011.jpg)
(http://i176.photobucket.com/albums/w168/zukgod1/Picture012.jpg)
(http://i176.photobucket.com/albums/w168/zukgod1/Picture013.jpg)
(http://i176.photobucket.com/albums/w168/zukgod1/Picture014.jpg)
(http://i176.photobucket.com/albums/w168/zukgod1/Picture017.jpg)
(http://i176.photobucket.com/albums/w168/zukgod1/Picture023.jpg)