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Engine Specific Info and Questions => TDI Engine -General Info => Topic started by: oldskool rich on June 20, 2008, 07:28:17 pm

Title: PD bottom end in a 1Z
Post by: oldskool rich on June 20, 2008, 07:28:17 pm

tryna make my 1Z a bit stronger
got sum PD pistons and rods, found out i need the PD crank, then found out it doesnt fit the 1Z pully, got it machined to fit, now today i tried it out in the 1Z only to find that all 4 rods hit the intermediate shaft and one hits the block where the oil pump fits on  :cry:

so i ground 5mm off the block and changed to the AAZ intermed shaft (its thinner), now just the 1st rod hits the gear on the end of the shaft, how can i get around this? i filed a tiny bit off the rod, probly less than a gram, i know this is bad but surly it wont make that much difference, i cant realy cut any thing off the gear that powers the oil and vacume pump can i? it only just brushes it

any ideas? i thort people have done this before?

can i take more off the rod and then take sum off the others until they weigh the same?

Title: PD bottom end in a 1Z
Post by: andy2 on June 21, 2008, 10:48:09 am

It might be easier to use the ALH TDI engine if you possibly could as the Pd parts would be a direct fit.

Title: PD bottom end in a 1Z
Post by: oldskool rich on June 21, 2008, 11:13:27 am

its a bit late for a block change.

just want to know if its possible to shave a bit off the rods?

Title: PD bottom end in a 1Z
Post by: RabbitGTDguy on June 21, 2008, 02:04:39 pm

depending on "how much" needs to be shaved you should rebalance all within the same. Taking off the big end to clear though would compromise the integrity of the rod depending on "how much" you need to remove to get it to clear.

Joe

Title: PD bottom end in a 1Z
Post by: itzdshtz on June 21, 2008, 03:15:52 pm

When we were converting GTI engines from 1.6 to 1.9 ( 16 valve Oettinger) around 1980, we had to grind out the block to make space for the longer stroke crankshafts.

Another modification that we had to do was to machine the gear on the intermediate shaft narrower, to about 7 or 8mm wide, so that the conrod had enough clearance.

Now I haven't checked a 1Z block for a while to see if it has the same clearance problem that the old 1.6 had, but I would prefer to do this, grinding a chunk out of your conrod is not good practice.

   Herman

Title: PD bottom end in a 1Z
Post by: oldskool rich on June 21, 2008, 05:05:37 pm

im talking maybe 1mm tops off the rod, how much can i machine off the intermediate gear safely? i dont want it to mess up when im driving, i dont want to structuraly damage the rods but at the same time i dont want oil starvation.

Title: PD bottom end in a 1Z
Post by: itzdshtz on June 21, 2008, 08:22:46 pm

If you look at the gear, you can see the wear pattern of the oil pump gear, you can machine quite a bit of the gear off that is doing nothing.

  Herman

Title: PD bottom end in a 1Z
Post by: oldskool rich on June 22, 2008, 05:37:30 pm

safe, im on it, ill do the gear. as for rods, ive already took a gram or 2 off one, shall i match them up? :roll:

Title: PD bottom end in a 1Z
Post by: itzdshtz on June 22, 2008, 08:22:26 pm

If you are going to machine  the gear down, make sure that you don't overheat it and loose the hardness of the teeth, grinding it off and end up with a gear thats blue is not a good thing.

Where did you remove the material from your connecting rod?

   Herman