VWDiesel.net The IDI, TDI, and mTDI source.
Engine Specific Info and Questions => IDI Engine => Topic started by: boosted_diesel_84 on July 30, 2008, 04:00:24 pm
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Heres the MOD List
The Block- hot tanked, cleaned, bored and honed .0020, new intermediate shaft bearings
Rotating assembly-
Crank- forged, polished, balanced,
Rods-forged, polished,balanced, weighed
Pistons-Forged, ceramic coated, dry film lube, balanced,
flywheel-lightened to 8lb. balanced
(all balancing within 1/10 of a gram) better than NASCAR Spec, which in under a gram)
Head-Cleaned, Port and Polished, New bronze valve guides, Stainless Steel valves, radius cut seats, blended, milled, lash adjusted, flow tested (see sheets on last page)
Other MODS
-36mm oil pump
-Windage Tray
-Spec Stage 2 Clutch
-APR Head Studs
-1.9 MLS HG
-Passenger Performance 2.5 downpipe, into 3 in. exhaust with 4 in. tip, no muffler
-Passenger Performance 3in. Intake Manifold
-GTD Nozzles
-Built and Modified Pump
-EGT gauge
-K24 turbo, rebuilt, ceramic coated in and out, port and polished, wastegate valve ground
-Stock exhaust manifold, ported and polished, and ceramic coated.
-SRT-4 FMIC
-2.5in intercooler piping
-german bearings
and for the nay sayers
-1 piece glyco thrust main bearings,
-New Alt, and Starter
-Relocated Battery to trunk
-New waterpump, timing belt, ac./ belts, inj lines, R32 blue Valve cover,
-NEUspeed 4 point strut tie bar.
And a crap load more i cant remember. hope u like
well finally, after tearing down my 1.6 TD almost a year ago, i am putting it back together, i have spent well over $6,000 on the motor alone, my goal for this project is to build a very reliable fuel efficient vehicle for daily duty, and still be fun to drive, but not sacrificing fuel mileage for power.
first i started by taking my block and head to Air Cooled Engines Plus, a local VW machine shop that is amazing, he hot tanked my block, bored and honed it 20 over, cleaned it, and put new intermediate shaft bearings in, polished and balanced the crank, rods, pistons, flywheel and lightened it, ceramic coated and dry film lubricated, my new Kolbenschmidt pistons, ported, polished and ceramic coated my exhaust manifold, Passenger Performance downpipe, turbo housing, which the turbo is being rebuilt by G Pop shop. I also just sent my intake manifold to Passenger so they can make the bad azz one they make.
he reworked the head, with new bronze valve guides, new stainless steel valves, radius cut valve seat, with a performance grind, ported and flow tested to flow 25% over stock without losing velocity, i will post the flow sheets showing stock to now in a few days. the head was then milled then cleaned.
i have ARP hardware, a Spec stage 2 clutch, built injection pump, GTD injectors, windage tray, 36 mm oil pump, Good German bearings and gaskets, srt-4 neon front mount intercooler, Egt gauge and probe from Aircraft spruce, all new belts, hoses, accessories, glow plugs, relocated battery to trunk to have more room for intercooler piping, and anything else that is a wear item was replaced. here are some pics, i hope to have it running soon, let me know what you think.
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos630.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos631.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos632.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos633.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos634.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos635.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos637.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos638.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos639.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos686.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos687.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos688.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos689.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos690.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos691.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos692.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos693.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos694.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos695.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos700.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos701.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos702.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos703.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos706.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos707.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos708.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos709.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos710.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos711.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/July272008photos713.jpg) :twisted:
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Did you have the block decked?In the one picture it seems you can see the stone marks.
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Did you have the block decked?In the one picture it seems you can see the stone marks.
no, clearances were close enough with just the head milled, its just marks from when it was machined from factory, and my camera picks up fine details like that,
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Where in OH are you close to? I'm near dayton. Haven't heard of air cooled engines plus. I like what you have done. I've dreamed to do all that.
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Me too. OHIO where?
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Tiffin ohio, to be exact.
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Not to jack your thread. I am up in Bowling green and perrysburg quite often. I'm moving there this fall. Haven't been in holmes county. Back to your engine looks good i'm very jealous. Can't wait for a start up vid!
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Really nice job! You have clearly built a VERY nice TD. I noticed your headstuds are ARP's but the mains and rod bolts look stock.
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Really nice job! You have clearly built a VERY nice TD. I noticed your headstuds are ARP's but the mains and rod bolts look stock.
yea.. i had it in my original plan, but after i purchased everything and went way over my budget, i just cant afford to spend money on that, especially since the motor does not spin that high, the rod bolts are just kind of a bragging right, plus i need to be driving this thing asap. so i cannot wait any longer.
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Nice buildup i like the way u waited and put alot of pics and info all at once can't wait to see her get done
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Awesome build up! I'm in ohio too, near dayton. A diesel g2g should happen...
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Another Ohio dubber. Good to know there is a machine shop that's at least in the same state that knows VW's. I was wondering where to have the work done on my TDI engine. Looks great!
Brendan
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Awesome build up! I'm in ohio too, near dayton. A diesel g2g should happen...
deffinetly, lets put something together, like 2nd saturday in sept. or something, just far enough away everyone can make plans for it.
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Another Ohio dubber. Good to know there is a machine shop that's at least in the same state that knows VW's. I was wondering where to have the work done on my TDI engine. Looks great!
Brendan
yea, he is an awesome machinist, done it all, and great prices, he charged me $1,500 to hot tank the block, bore, hone, clean, install intermediate shaft bearings, redo the head, new stainless valves, port work, all the ceramic coating, balancing, lightening the flywheel, flow testing the head, and everything else mentioned in the first post.
if you want to talk to him heres his info
Air Cooled Engines Plus
John & Joanie
419-443-8987
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Writing that number down now. Let me know on the date and place guys. I've got some MX races coming up around then.
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Heres a little update, SHE Finally runs!! after 1 year and 3 months build time, here are some pics of when i just got it together some stuff has changed and i will post more pics soon, the intake setup is only temporary until i rig up my FMIC. hope you like
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/dieselstartup010.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/dieselstartup009.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/dieselstartup006.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/dieselstartup004.jpg)
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do you guys run 25psi right after rebuilds?
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No, definetly not, i have to break the SPEC stage 2 clutch in for 800 miles with no launching or full throttle runs, and not run motor hard for about 1000 miles so everything can seat in properly, but shes running way better than it ever has. lol, this is what over $6,100 in a old VW diesel motor looks like, but to me its worth it and way better than just going out and buying a new POS KIA
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uhhh 6 grand in an old engine?
You basically made a new one. Nothing about that engine resembles an old engine at all. Did you get new injectors? and the injection pump?
the block, rods, pistons and head are MINT. and from the sounds of it so is everything else :roll:
I wish VW made these engines new, but i see you took it into your own hands to make your own! nicely done. Looks really sharp.
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yes, GTD nozzles and highly modified pump
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Here are the Latest photos of the build, the valve cover is painted VW R32 golf blue, which i think is a freakin cool color,
yea, i kno the blue wire loom is a little rice, but i think it looks good on this application, let me know what you all think,
oh yea, i know the vacuum line from LDA is unhooked, i took it off to put the Passenger sticker on, and didnt put it on before the photo was taken.
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/finishpicofTD007.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/finishpicofTD006.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/finishpicofTD005.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/finishpicofTD003.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/finishpicofTD002.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/finishpicofTD001.jpg)
And just for fun, heres a good before pic of the mess, haha
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/quantumandjetta001.jpg)
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night and day...
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no IC?
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nice job that looks great!!! your Build and zukgod1's are some of the guys who got me fired up on a diesel project!
get you a IC on there...you can mount one and do it nicely in a day easy!
I also see a bigger AC diesel radiator in your future :lol:
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looks great, but get rid of the couple cheezy looking hose clamps so they all look good and match. :)
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yes, as i stated above, the intake setup is only temporary, i have a srt-4 neon FMIC and all the intake tubes, but i had to get the car out of the garage i was keeping it at, and its cold working outside, so when it warms a bit i will install it, clamps are temp also, just what i had laying around that fit. but thanks for the input!
also car has factory A/C so i assume it has the bigger rad? i dont know if il need it though, she runs really cool, all the ceramic coating makes a huge difference
-Jack-
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yea that looks bad ass! and it's even a factory turbo jetta! priceless!!!
i bet your just itching to see what she can do?
Duane
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yea that looks bad ass! and it's even a factory turbo jetta! priceless!!!
i bet your just itching to see what she can do?
Duane
yea, the turbo sounds so amazing, its sooo hard not to romp on it, but ive been good, have not gone much past 1/4 throttle. when its all broke in il make a video of it, and i can tell, it already wants more fuel, haha
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that thing cost a lot... but much more fun than a hopped up gasser... hopped up gasser = will always drink fuel even if driven lightly... hopped up diesel = will only drink fuel when you're flogging it. :twisted:
i love when people say "you could have bought a new car for that!" what... a domestic piece of trash? lol... from a company thats going bankrupt??? no thanks... honda/toyota... the price range will get you a lifeless car that isn't fun to drive.
not to rant here or anything, but i get a kick out of it when someone says that north americans should buy domestic... to support china/korea/mexico? yup i really should support communism!!! :lol:
sorry for cluttering up your thread man, but totally awesome build!!! you did the right choice 8)
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yea, he is an awesome machinist, done it all, and great prices, he charged me $1,500 to hot tank the block,...
Glad to see some are still hot tanking. Its the only way I know of to get all the rust can scale out of the block.
Where did you get your pistions ceramic coated ? I see you said Air Cooled did it, but I assume they sent them to someone else ?
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Glad to see some are still hot tanking. Its the only way I know of to get all the rust can scale out of the block.
Where did you get your pistions ceramic coated ? I see you said Air Cooled did it, but I assume they sent them to someone else ?
Yea, hot tanking is deffenitly the best way, baking a block is a bad idea.
He coated my pistons, turbo housing and exhaust manifold in house, like i said he is an amazing machinist and has really good prices.
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Got some final assm. pics? What charger do you have?
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Got some final assm. pics? What charger do you have?
i will upload more pics later, turbo is a k24 that was ported, ceramic coated in and out, assembled and balanced by G-Pop Shop in arizona, wastegate seat and valve were also ground to ensure proper seating ability. stock ex. mani that was ported, and ceramic coated in and out, and has egt probe.
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Who coated it? most companies won't coat the inside of turbo componets.
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Who coated it? most companies won't coat the inside of turbo componets.
Air-Cooled Engines Plus, the same machine shop that did all my machining
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I guess some one already asked but do they do it in house? I'm now an hour away from ACEP i tiffin right? So i may have them do some work for me.
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here are my flow sheets Finally, ive been really busy so i have not had any time to post them,
my intake flow is 130, up from 107, exhaust is at 111.2 up from 98.7 and all this was done without hurting velocity but actually improving it, yea, the head could have flowed over 200 cfm easily, but it would kill velocity and run like poo poo. but i am very happy with the results, can runs amazing, night and day from before. and as you can see from my flow numbers to "TheMan53" John at Air cooled engines is very consistant, as both are heads flow almost identical. enjoy!
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/dieselflowchart001.jpg)
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/dieselflowchart002.jpg)
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Passenger is just down the street from me! I should apply there :D looks like they make neat stuff. :wink:
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I thought those numbers looked familiar, but they weren't mine at all. Just looked like the same paper.
As an added note the guys name is John and really great to deal with. I didn't have ANY troubles but if I would have he is the kind of guy that would have been straight up with me. I guarantee he would have called me to tell me if something was wrong rather than finding out later.
I can't wait to get mine all together...maybe this spring.
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Wow, those are decent flow numbers for stock valve size!!! I'm actually surprised. :D Nice indeed!
Brendan
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yea, John is a great machinist and really knows his stuff. he is actually working a booth at the PRI show right now,
but as a side note, a few years back he did an audi 5 cyl head for me, with stock valves and cam ant it flowed almost 200 cfm, and that thing really ran awesome, it was in an audi 90, non quattro unfortunatly, but at the track with sticky tires, the fastest i could run was a 16.5 only cause it would spin all the way thru 3rd gear and chirp 4th. i just could not get traction. i would let off as soon as it spun, and would get back on it and it would just spin again.
but on the street it was actually better, it walked a honda del sol with a JDM B18 V-Tec with headers, intake, etc. so it was a huge difference what his port work can do,
his flow bench is crazy cool, it can masure velocity, swirl, tumble, port map along with flow numbers and other things, its really cool. heres a pic of the flow bench he hand built!
(http://i157.photobucket.com/albums/t65/jack_weisenburger_2006/AirCooledFP-1.jpg)
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Very nice numbers! That should make a big difference when you get it going :)
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Very nice numbers! That should make a big difference when you get it going :)
actually its already going, runs awesome boosts hard and breaks the tires loose with no effort and i have not gone past 1/4 throttle while the motor is still breaking in. i have almost 500 miles on it.