VWDiesel.net The IDI, TDI, and mTDI source.
Engine Specific Info and Questions => TDI Engine -General Info => Topic started by: RabbitGTDguy on September 03, 2005, 06:08:36 pm
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Lucas' definative vision...
Ok...mine...
More to come...
The original... IDI TD motor now sold...was great at 23psi :)
(http://i18.photobucket.com/albums/b109/joeallison_99/Pavilion2.jpg)
The new wheels...Centra's, W.Germany circa late 80's 15x7 on Falken Ziex rubber
(http://i18.photobucket.com/albums/b109/joeallison_99/100_1762.jpg)
My homemade AWIC
(http://i18.photobucket.com/albums/b109/joeallison_99/100_1712.jpg)
But MOST importantly... the start of something great!
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_1809.jpg)
And cummins beige in honor of...TBA
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_1836.jpg)
and before anyone asks...no, i didn't paint the sealing surfaces, etc. for the oil filter flange, water pump inlets, etc... I used a "priming" jelly that I've come to like...just apply it to surface, paint and then peel once the paint dries...works great and takes alot of time out of masking...
Its great to be back. Have been here now and again but finally settled and moved for at least two years... New job...new motor...new plans! Hope to see more of Marc ...missed talkin to you guys!
Joe
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And cummins beige in honor of...TBA
Holset HX35?
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Hey Joe did you used to be the moderator back in the day on the old GTD hostboard forum? Hope you got my pm from tdi club Re: the electrics for your tdi engine.
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Hmm....Holset...now thats an idea. T3 is actually what I had lined up...with some other nice additons to what you see...
Anton...no, didn't get your post about electronics at TDIclub...only one i got was regarding the fact that the MAF, and a few other bits were missing. Was looking for what you needed to get for the electronics. Now I believe I've solid on going the mechanical route... PM me if you know a price though...might have someone lookin
Yes...I am the old moderator from hostboard...Marc (redrotors) and I constructed the orginal site...
Joe
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And cummins beige in honor of...TBA
Cummins 4bt injection pump?
PS - Welcome back! :D
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Hey Joe sorry I must have forgot to pm you back but I thought I did. Anyway he was going through a closing deal so I dont think he has it anymore now. I would go A4 edc though if you were gona run edc. Much better control and tunabilty. Iv not been on here much myself been mostly on tdiclub trying to figure out my engine. I remember couple of years back reading the whole old GTD forum Its like a college course for diesels I learnt so much from it. Its nice to see some poeple on here that I remember from the old one! Im hopefully gona stick around here a bit more often now.
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thanks anton! Its good to be back and see that things have expanded...
I had decided to to go EDC a while back :) Mechanically gives me for flex for what I want to do on the turbo side of things as well as other modifications...
Joe
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Mechanical is old skool!! way to go if I may say so :lol:
I would go mechanical but the cost of getting a hybrid pump here in the UK doesnt appeal to me and besides I got full A4 edc with my engine so I wont have a problem controling my vnt20 either.
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I am curious, what 020 tranny were you running with the TD?
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looks sweet ..the engine i built for my project was cummins beige then i put it in my sisters 98 tdi and painted red to match her car..loooking good..after i get my new 95 passat glx wagon to tdi swap done i'll be doing my mechanical tdi jetta up..should be sweet.. when blake moves back to ny we can have a rabbitation here or something a mechanical tdi cruise ha..his will be done and your and maybe mine..sweet.
later
Deo
\x/ hillfolk!
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hey that ic is sweet!! thats what ihave started myself,,what are the core/tanks from,,iwas gonna make my own tanks from sheet alu,,,,,looks good though,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,hey deo,how long do u think those cummins isb fuel pumps would last ,if u used them to pump water/coolant mix thru watercooled ic?????figured coolant would provide some lube on pump,,,hmm,,ill try and get the rest of em,,i know we have 12 pump kits at work,so thats 12 school busses,and 12 "old but good" isb lift pumps for me!,
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I am curious, what 020 tranny were you running with the TD?
The tranny was an FN for the IDI TD setup. No modification.
The new tranny....huff... for the m-tdi setup will be a combination that I have come up with to get me as close to the TDI's Final as well as its gearing but in the 020 setup. LSD will be added later as well. I'm not a fan of the feel of cable shift. Not to mention I don't believe they are the cure all for the swaps. I was talking to a friend and mechanic for VW and he has seen quite a few TDI's themselves chipped and stock come in with broken trannies. The 02a 02j etc. do have their merits...but, not a cure all IMO.
AWIC core is from a turbocoupe, jacket was welded by my friend ...its a nice unit and probably is overkill for the application since we had made it for a lysholm 16v Corrado project i was working on a few years ago. But...it'll be going on the rabbit. Just need to figure out how I want it mounted.
Joe
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More progress...well, pics.
While I've been waiting to source the remaining pistons I want to use and get them coated...as well as things to sell so i can get some more hardware.... I've been building, sandblasting and working away at the little details for the motor...and rest of the car...Lots of pics.. :)
Meanwhile, all gaskets, bearings, etc. are anxiously awaiting install into the motor so I can get this going :)
The head...worked the weekend on cleaning and getting ready to port match it... MAN you would not believe how crudy those intake ports were!!! Still have a little to clean out of it!
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_1921.jpg)
Its details...all were sandblasted and precleaned before painting...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_1915.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_1920.jpg)
Maybe I'm getting a bit crazy...even did the injector hold downs in Cummins Beige... Not that much is...just the block, and what you see so far besides all four calipers :)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_1918.jpg)
Working on the mechanical pump too...still trying to source a used LDA top, assembly for some test and comparisons. Working on the gov. assembly of the pump and figuring out what I want to do for a sprocket...think this is my ticket, turned backwards, against the mkIV adjustment hub and about 1/4 of material taken off the sprocket... ADJUSTABLE SPROCKET ....Mmm...easily timing advance adjustments. :)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_1874.jpg)
Was going to use a 1.9 AAZ sprocket...but have been unable to find one...or even a picture. From what I remember though, this is very beefy compared to the AAZ unit...
And working on the intake manifold arrangement as well. My plenum style G60 intake manifold that I'm going to have to port match the daylights out of to make the D ports on the TDI head...hoping, there is enough material...its close...should be fun :) Also, my modified G60 boost return portion of the throttle body to make the inlet portion of the manifold from the AWIC once its hooked up.
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_1925.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_1928.jpg)
I won't have interference issues with the turbo since I'm running a back set turbo like I was running previously on the build IDI TD in the car.
So...some progress :)
Joe
p.s. Deo...any luck on finding those pistons :) :) :) Probably got slammed with a snowstorm with your luck from your PM i got on Fred's...
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Joe looks good i painted my idi 1.6L td that color.. phew where to start ..basically i haven't found the piston i thought i had..i did find a set i had sanded down the tops to be level with the piston deck it the oem valve relief around the combustion bowl etc..if you know what i mean i e th ewhole top of the piston is level with the bottom of the vlave relief area..i was hoping to lower the compression a little..any how you can have that set if you want as i dropped one..i will look and see which one ..th edropped one ie dropped on th efloor cracked the piston ..so that one is junk..if you took another piston and shaved the top it woiuld be fine..or i could shave atop for ya so it would match?...i have another box to look in and two engines to take apart to find a piston if you don't want the shaved set...custom!!!
later
deo
\x/ hillfolk!
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I'm not sure about the "shaved" set. I'd like to see pictures first...I do have one of these you could shave down though. PM me with what your looking to get... Also...how much did you take off and was it equal on each piston. Did you use a lathe to do it or what? If your willing to look in the other motors...that may be the best route but it is possible I could be interested in lower the CR...especially since I'm also getting these coated. I'm not sure how much i like "no" valve depressions on the pistons though.
Yeap...work is coming along on it...just getting this piston straightened around has been the biggest battle...
Joe
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Great work, Joe, thanks for the update. :)
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Thanks Jake... was working on some more details today and prepping the head and the intake manifold for the port matching job :) Fun stuff. Can't wait. More anxious for finding my pistons I need :)
Joe
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Hey Joe thought Id wonder over to the past of my IDI and this forum and found your project! Looking very sweet indeed. Thanks for the comments on mine on tdiclub. Looking forward to some more picture updates!
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Yeap...can't wait. I've been waiting for a TDI for years and its finally a partial reality :) More than glad to leave the comments on yours...its very nice...and coming along nicely!
Joe
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Updates, Updates...
For anyone following the thread.... alot of progress came today when I got my pistons back from the machine shop...
Before machining...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_1935.jpg)
After machining to bring down the CR slightly to allow for more fuel/boost as well as elminate hot spots associated with the lip...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2048.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2050.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2049.jpg)
CR should now be around 17.5:1 after ceramic coating which I hope they will go in for through SwainTech next week :) Going to CC the pistons and also see where I am at prior to ceramic and after though its easily figurable, I'd like to run through it again.
Also, using the cummins pump on my application and needed to find a solution to the injection pump pulley since the nose on the cummins pump is shorter than a TDI unit. I liked the stoutness of the MK4 style TDI injection pump sprocket and the fact that it is "adjustable" for timing without loosing the pump...so I went the route of having this machined to fit. Problem was, turned correctly on the injection pump pulley's hub it stuck out to far and wouldn't align. Turn it around backwards and it would align but would hit against the injection pump bracket, its "bubble" on the one. So...problem fixed :)
Before:
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_1874.jpg)
After:
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2045.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2057.jpg)
Now, everything is here with the exception of Swaintech doing the pistons for me in TBC and PC-9 and the need to get Racewares... March, here we come!
A few more pics... Will readily start working on assembling the bottom end tomorrow. Have to press in new int. shaft bearings, then do the crank, etc. while the pistons are being done.
Gov. swap on the Cummins pump went like a charm and now with the added adjustablity of the injection pump sprocket on the fly should make for a really nice setup come spring. Also, to those wanting to clue in on using the cummins pump, give me a shout, IDI or TDI and I can help you out.
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2015.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2012.jpg)
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Hey Joe great update!! Im so jelous of what you did with your pistons :twisted: I was going to take the same route but couldnt source any spare pistons to work with now my engine is in and I dont want to drop the bottom end. Also glad you got your pump sprocket sorted...now get it together! Im on a long holiday in Russia at the mo drinking really horrible vodka so no time for my car at the mo :cry: but not long left....keep us updated your doing great :D
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Def. will keep the updates coming. The ball should really be moving now, especially once the pistons get back from SwainTech. If anyone has a stock TDI piston they could "cc" for me, I lost the information I had recorded on a computer that crashed between the time I dropped the pistons off and I received them back. I had CC'd the ALH piston prior so I could see "exactly" what the CR would be when they were machined, but I only recorded it on the computer... it'd be great if someone had one they could measure for me. I did the machined ones tonight and got 29cc on each filling the bowl as well as the valve impressions...
I slate the CR to be around 17.5:1 once they come back from coating... Def. optimal for high boost :) and fuel :)
Plan is to have the motor done by the end of next month I hope...in the car for March or April...
Of course...never know :) But it def. was worth ripping the bottom end apart and doing this nice and neat how I always wanted it
Anton! can't wait to see more progress pics on yours too...
Joe
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Joe, Looks nice...I've been driving mine since sunday...mummn mines got some issues i'll start a new thread not to high jack yours....tell you what though.... TONS TOND OF TORQUE AND TRACTOR NOISE..later
Deo
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No sooner did the pistons get back that I now sent them away again :(
But for coating at SwainTech this time :) TBC and PC-9 Supposedly a week turn around and they'll arrive tomorrow...so maybe sometime next week they will be back!
Joe
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Well... pistons came back from SwainTech already today... awesome... a week turnaround almost to the hour it seems...awesome guys...
Here are some pics of the TBC top coating and the PC-9 dry film coating on the skirts...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2071.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2070.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2072.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2073.jpg)
And I'm almost ready to install them believe it or not. Got the crank installed and am hopefully going to finish install the seals and their carriers tonight or tomorrow... have to wait for a new paper rear gasket to come in again though for the rear...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2069.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2067.jpg)
Wahoo...going to be able to get movin now!
Joe
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Awesome!! The coating looks great.
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Joe,
Just curious, what did it run to get em coated? That looks good,
Thanks,
Deo
\x/ hillfolk
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check out SwainTech's site for all the pricing info as depending on what kind of coatings you want to run it depends... mine ended up at around 38 a piston...
www.swaintech.com
Marc did similar on the Blue Monster AHU he just sold here in the fall, however, I believe his were TBC top coating but the Poly-Moly on the sides instead of PC-9.
Joe
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Those pistons look great, Joe... Makes me think more seriously about coating mine! :)
I'm interested in hearing from anyone who has run any coatings on their piston crowns, valve faces, or combustion chamber surfaces for any length of time and gotten a chance to inspect it to see how it held up later.
On a 1.6lTD I tried a thermal barrier coating on the valve faces once upon a time, not from swain tech though it was from http://www.performancecoatings.com . Some of the coated valves didn't hold up as well as I would have liked to see, the coating showed some pitting after head removal and inspection! :?
Come to think of it, I have had generally negative results with every other time I have tried engine coatings, but maybe it's because I used the wrong place. A brand new oil pump I had just blueprinted got nicked and it's walls scored during dry-film impregnation and ended up putting out less oil pressure than the several hundred thousand mile old used oil pump it replaced. Exhaust coating results have also been mixed. I will grant that the coating does seem to effectively reduce the transfer of heat. A stainless steel coated downpipe looked great after coating and still looks great years later (as you'd expect from stainless...) but a coated 1.6lTD exhaust manifold ended up after a few years with some kinda ugly rust specs peeking through what used to be a nice looking coating. Any successful, or not so successful engine coating experiences on here?
I didn't mean to derail Joe's thread too much (please carry on Joe, and keep up the excellent reporting!)
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Wasn't feeling well today so I stayed home...ended up getting antzy though and thought I'd wrench downstairs for a while...got some stuff done:)
After a nice delay due to some tq differences between the intergrated rear main seal/carrier and the old style press in seal w/ paper gasket and carrier...got it installed, and the block/crank assembly onto the stand...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2102.jpg)
Also...can't beat the quality of OEM Goetze rings... I was impressed with the used ones and how much "in spec" they were even at 126k when I tore the motor down this fall...barely showed signs of use. Most impressed with the new units out of the box and now installed as well... glad I chose the OEM route instead of going Total Seal
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2079.jpg)
Always start with good materials
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2119.jpg)
Cleaning Gasket surface (night and day pic) prior to piston install...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2106.jpg)
Ready to install machined and coated pistons...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2107.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2111.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2110.jpg)
Tick tick tick...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2114.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2115.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2117.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2120.jpg)
Looks like the bottom end can be done by the end of the week! Wahoo!
On a seperate note. I had looked into performancecoatings.com before but after weighing it heavily, talking to SwainTech and even those that have put their stuff to the test, there was no substitute for having the right company with the right prep equipment and application/curing equipment to do it once and do it right. I've heard horror stories of even more hot spots and such from unevenly dispersed DIY coatings as well as wear issues, etc. Swain also took the time to explain that the DIY coatings aren't nearly the same formula as what they use. I didn't have any problems paying the money to have it done through them for the insurance...besides, they started it all in the first place!
Joe
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looks great joe..get it running soon !!! ...on another note ..total seal doesn't make any vw tdi rings...you send them your goetz factory ring set and they machine th etop ring fro the extra zero gap peiece..so if you do like blake did you still have th esame rings you used but total seal just mods the top ring for less leak down etc...
Later
deo
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that i knew :) just glad I left them the way they are...like i said. Crazy in spec, well within spec at 126k ...i'm very happy with that...
Thanks for the comps... :) It'll be running in late march-early april...no rush as the GTD doesn't see winter weather and I'm takin my time ...still lots to do...
Joe
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Wasn't feeling well today so I stayed home...ended up getting antzy though and thought I'd wrench downstairs for a while...got some stuff done:)
After a nice delay due to some tq differences between the intergrated rear main seal/carrier and the old style press in seal w/ paper gasket and carrier...got it installed, and the block/crank assembly onto the stand...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2102.jpg)
Also...can't beat the quality of OEM Goetze rings... I was impressed with the used ones and how much "in spec" they were even at 126k when I tore the motor down this fall...barely showed signs of use. Most impressed with the new units out of the box and now installed as well... glad I chose the OEM route instead of going Total Seal
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2079.jpg)
Always start with good materials
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2119.jpg)
Cleaning Gasket surface (night and day pic) prior to piston install...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2106.jpg)
Ready to install machined and coated pistons...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2107.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2111.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2110.jpg)
Tick tick tick...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2114.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2115.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2117.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2120.jpg)
Looks like the bottom end can be done by the end of the week! Wahoo!
On a seperate note. I had looked into performancecoatings.com before but after weighing it heavily, talking to SwainTech and even those that have put their stuff to the test, there was no substitute for having the right company with the right prep equipment and application/curing equipment to do it once and do it right. I've heard horror stories of even more hot spots and such from unevenly dispersed DIY coatings as well as wear issues, etc. Swain also took the time to explain that the DIY coatings aren't nearly the same formula as what they use. I didn't have any problems paying the money to have it done through them for the insurance...besides, they started it all in the first place!
Joe[/quotedude,,when i got a rear seal ,,they wanted 80+,,grab an old school seal carrier,,much cheaper,,and use a seal installer on the crank,,,,,,and get it right,,i used goetze rings,,they were modified by total seal,,,my worst ring gap was 17 thou,,figured it would be ok w/ total seals,,,i may have mine goin this week,,still have to add lift pump,guages,,finish moving supply+return lines,,fit rad+hoses,,battery 90 deg. mod,,shifter linkage,,boost control lines,and controller,boost tubing from turbo to intake,,water injection,,,,,wire up all the guages,,ive got some nice plastic+foam insulation,to complete a "shroud " onthe sides of the rad,,the stock paper deflectors have had it,,,,relocated fuelfilter to below right side "framerail",,looks good,,makin a partial rite side inner fender liner,,to protect belts too,,,,,,,lotta crap to do,,,only 2-3 hours a nite during week,,,,,,,if not this weekend maybe next week sometime,hey lemme know when uare ready for fireup,,i have a nice priming tool
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Thanks... good to hear there is another, this motor should be real tight :) I used the old school carrier with a press in seal and paper gasket. I could have gotten the intergrated...found a good price on them actually, but already had all the parts for the old style. I didn't need a tool to install though, made my own :) All worked out quite well...
On the primer, sound good...but i think I'm probably going to pop the lines and let the lift pump/electric assist pump i install prime the beast. What do you have? One of those ball thingys you attach to the pump supply line at the pump and squeeze to prime?
I'm lookin at March/April to have this in and running...many other things to do...
Joe
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Maybe I missed it, but what kind of pump are you using for the prime/lift pump? Do you have it wired in like an EFI pump to prime when the ignition is turned on? Thanks.
Looking really nice, I am jealous!
Brendan
84 Scirocco 8v
00 Camaro L36 M49
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I haven't decided on exactly "what" pump I want to use for the lift pump yet... I have several options. An inline low pressure FI pump from one of several CIS cars I have around. Also have access to the in-tank units as well...which could be a possibility. I also have considered the lift pump from a Dodge/Cummins motor as well that is made by Carter. All would be well suited for the job its just deciding which one I want to use. If I do go the VW route, I'll wire it just as it would be in a gas setting. Relay and all. Otherwise, it'll feed from the ignition contact on the pump solenoid. That part of "all the other stuff" once the motor is done :) I also have a fuel cooler I'll be running on the return line as well.
Joe
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use one from an isb cummins,,thats what i got,,,,should be able to get one for around 50 or so,,,i did a ton of 0504replacement campaigns at work,so i have a few spares,,um i think they flow like 72gph or 96 or something,,i dont remember offhand,but its plenty,i know ido get like 15 psi at the inj.pump inlet,nice,,,even on a normal diesel,use a lift pump,,my old 1.6 jetta td used to fallflat at the strip in3rd on up,,starving for fuel,,,couldnt feel it on the street though,its a good idea to assist any bosch ve witha lift pump,, ,,i got it set for key on,,but you could make it running only,by using an oilpsi switch ,,,, mine is "quick+dirty",mounted back near where the gasser pumpwould be,,idid plumb it with nice german hose+clamps though,,,the isb pump has 12mm(ithink) banjos,,the one igot is the "same" but has pipe threads,,i put 3/8 hose barbs on them,,i got my orig pump thru work at napa,,,they have like 6 different carter pumps avalable,,,the differences are mostly hose hookup differences,but they have some with more or less flow too,,,,but find one of those carters theyare fine,,,i maytry to use one for my water to air ic,,,,but if ido,,imayhave to use coolant for lubrication for the pump,,,,theyare a vane pump,,
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we'll see...lots of options... :)
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Forward Progress...the bottom end is pretty much done. Going to wait to put on the oil pan as I think I'm going to pick up a windage tray just to make things complete down there. Have to wait for some funds though... :)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2121.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2122.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2123.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2126.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2125.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2124.jpg)
Guess I'll start in on the port work on the head and manifolds and possibly some more pump work too this weekend as I find more ins and outs of the 4bt pump and where to tweak...
Joe
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looks nice..your keeping teh ac huh?..i guess the serp belt setup is the best route to go if your keeping teh ac..looks good..if my cut d valves work yoiu should try em hehe..later
Deo
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no, not keeping the A/C, the GTD never had A/C to begin with. The MK3 accessory bracket can be used with an alternator only by using a H20 pump serpentine belt and pulley which can be bought on the aftermarket or through the dealer for a fairly cheap price. I have no A/C or power steering...
I like the clean look of the serpentine setup and the less maintenence/ ease of changing the belt.
Joe
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yeah save a vr6 water pump pulley...it works good for that and its cheap..
later
deo
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its actually the euro non a/c version pulley for the 2.0 8v and its belt. The VR pulley doesn't line up the crank and is slightly different.
(http://www.futrellautowerks.com/images/20noackit_small.jpg)
Joe
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well joe i have updated my post about my tdi ..i have some pulley problems too..the part # you gave me is just the outer pulley..no hub or woodruff key part to bolt the pulley onto..argh gonna need to machine the tdi one now..so i have a $50 paper weight here..did your pulley from impex come with the hub?..they only show the pulley and a woodruff key as available..argh...?
any ideas?
thanks
Deo
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the hub comes as a factory part from Bosch, there is no VW p/n for it. You could try a bosch supplier... I responded to your post and remarked the same thing and a couple of options. The p/n to begin with was for the pulley only...found the thread with the quote in it...
Here is what I pull up from ETKA on the AAZ injection pump pulley...
028 130 111F
Either way...
The hub should work just the same and non of the hubs for the adjustable pulleys have woodruffs cut in them....they are a tight "press fit" on the shaft... the AAZ pumps with the adjustable hubs were the same way. Thus the reason why when talking on TDIclub, etc. regarding injection pump overhaul, etc. VW notes that if the hub is removed the pump must be reindexed to the hub in order to set timing correctly. Now...there are several marks that you can use for reference on the TDI pump hub and the woodruff spot on the shaft will help align for initial injection pump timing anyways which is how I plan to setup mine up, etc. for timing reference and then checking against the gauge...
Joe
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heh well i got no problems using the a1 brackets,pulleys ,motor mounts,,actually ditched that nastyharmonic balancer,a single v groove pulley is in its place,,,nasty heavy flywheel gone,and 6 pounder in place,,,nice spool up,,,,must be like 15 pounds gone from crank between pulleys/clutch,,it rocks,,,,,,,
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in the last thread we were talking about the pump sprocket...
Your using the small shaft IDI style injection pump with the 12mm head?
I am using a modified diesel MK1 bracket but not the injection pump portion... having to modify the timing belt cover backing plate slightly...no big deal. As for the hb and serp belt setup...i prefer that compared to the v belt. Did you ditch the TDI's timing belt setup all together; the self adjusting tensioner and the deflection pulley as well? Interesting...
Glad to hear you have it on the road... soon soon. Work is beginning on my AWIC setup as well as the head and a few other pics while waiting for the tax$$ to come through...
Joe
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in the last thread we were talking about the pump sprocket...
Your using the small shaft IDI style injection pump with the 12mm head?
I am using a modified diesel MK1 bracket but not the injection pump portion... having to modify the timing belt cover backing plate slightly...no big deal. As for the hb and serp belt setup...i prefer that compared to the v belt. Did you ditch the TDI's timing belt setup all together; the self adjusting tensioner and the deflection pulley as well? Interesting...
Glad to hear you have it on the road... soon soon. Work is beginning on my AWIC setup as well as the head and a few other pics while waiting for the tax$$ to come through...
Joe
come on joe,,git er done,,,,,,yea small shaft 12mm,,,,race 520 nozzles,,im likin that,,,iwas debating using a gas engine mount,and a ahu pump mount thatll work too,,,,um i sorta forgot to install a timing belt backing plate,,but it looks like ican still make up some bosses to mount the upper cover to,,i have no cover on it right now,,the upper cover that is ,,the lower cover is there,,,hey heres recycling,,i cut off the big long air intake from the old ac box,,,heated it with a heat gun,,and installed it in right fender to protect belts,and relocated fuelfilter,,,,,,,too much crapto deal with for serp belt setup,,i dont have ac anyways,,,,i was gonna use auto tensioner,for tim.belt,,but i figured it would be alsoa good idea to use that little roller on pump bracket too,,,soi removed the tensioner stud,replaced it w 1.6 td one,,and amrunning a 1.6 tensioner,w/a std tdi tim.belt,,,,my motor mount uses a hd mount,,bottom half filled w/ epoxy,,,whenweight of engine mounted in the car,,it doesnt rest on the epoxy part ya know???,i really like that,,,vibes arent bad at all,,or any worse than normal hd mounts,,,,,basically iused pulleys and stuff from the 79,,im sayin get it runnin with the easier setup for belts etc,,thanlater if you want put on the later stuff,,ibet at a glance,,some people wouldnt evenknow its a tdi,cause of pulleys etc,,,
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I already have all the stuff for the serp belt setup. Only thing you need is the non-ac water pump pulley and a belt. You can buy a kit for it for 40 bucks, belt included... :) In the future (i have an extra MK3 accessory bracket) I'll probably convert the 79 too if i keep it. I already have the alternator though for the mTDI setup, etc. from the MK3 application so I don't have much into it.
I'm workin as fast as I can to get it done with the funds alloted. Couple things came up here in the last few weeks with the 79 (namely the alternator because of overtightened v belts from the PO) that the funds just kinda dwindled away...plus, waiting to deliver on some parts I have from the MK2 I'm parting...
Working on the head port matching this weekend and the intake manifold though. Then...get the head back together. I've got Sprint764's to try initially as well. Want to try them and then decide from there which nozzle I really want to run once the car is running. :)
Joe
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That's gonna be an awesome Rabbit! I'm curious though, why are you using a 4bt pump? I thought the Bosch VE would handle this. Aren't they used on the M-B 240 & 300 D/TD's?
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i hear ya on the fundage man,,,,ive got almost 4500 in the engine/trans install stuff,,,,dont forget the lil stuff like fluids clamps,hoses all that little stuff added up,probably 100 clams or so,,,,ii had some brackets/pulleys accys hidden away,,,hardest part was finding where i hid some of the stuff on myself,,,,wish there was a smiley face that looks like "ripping hair out",just insert that one here
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i hear that... the grand total is creeping up here too... 900 for the engine just initially with 126k on it...then all the stuff for the rebuild plus the modifications I've made to the pistons and the coatings as well. Still need to get the racewares...waiting to bolt on the oil pan because I think I'm going to install a windage tray first. I've really been quite lucky though. Haven't tapped into my fiancee and I's joint acct. at all...all money has been from sale/trades on stuff, etc. Which the barter system worked so well everywhere. Plus, everything on the motor is new and OEM...no cheapy's :)
That's gonna be an awesome Rabbit! I'm curiuos though, why are you using a 4bt pump? I thought the Bosch VE would handle this. Aren't they used on the M-B 240 & 300 D/TD's?
Yes, I am using the Cummins 4bt pump, it is a Bosch VE rotary unit though. Most people doing the mTDI conversion are using non DI specific hybrid pumps. In some cases even, a complete 1.6TD pump turned to the max. in stock form. Others, and a better solution like hillfolk'r is using a hybrid consisting of the IDI TD pump internals and smaller mainshaft with a larger 12mm head.
My setup is a mechanical pump from a DI engine already, so...IMO its better fitted to the engine and is more likely to last longer and handle the injection pressures that the TDI engine demands vs. that of the hybrid pump. Plus, in my experience hearing the hybrid pump on my friends TDI Westy Synchro run vs. when we had the 4bt pump on and installed...it was NIGHT and DAY. Just initially off the bat with the smoothness and sound of the motor but then also with the power of the motor too. His drawback was that it smokes a little much for his liking but in a Vanagon part of the problem there is now his intercooler setup is too small for the fueling he has which is soon to be answered with an AWIC setup. I also have many flow improvements as well to the intake system as well as the head which I'm working on as we speak. So...its def. going to be fun!
On a seperate note... the pumps used on Merc 300D's, etc. that I have seen were all Bosch inlines...though, i've heard of a few that were VE rotary. 4bt's came in two varieties as well... the VE and the bosch inline too :) Now what I'd really like to see is the electronic VP44 be fitted to a TDI engine with custom CPU programming and I'd be all over that. The VP44 can handle ALOT more injection pressure vs. that of the VE pumps that were used on the TDI motors.
Joe
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yea do the windage tray i did,,,,,,,get the raceware main studs too,plus head studs,,thas what idid
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I'm probably gonna get divorced over this!!
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Def. doing the tray...just waiting for funds to come through.
Trying to find the "BEST" price on Racware studs for the head as well...haven't had much luck thus far. Did find a nice deal on yet another tranny (MK3) as well as a 6puck and reinforced PP tonight though :)
Joe
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Yes, I am using the Cummins 4bt pump, it is a Bosch VE rotary unit though. Most people doing the mTDI conversion are using non DI specific hybrid pumps. In some cases even, a complete 1.6TD pump turned to the max. in stock form. Others, and a better solution like hillfolk'r is using a hybrid consisting of the IDI TD pump internals and smaller mainshaft with a larger 12mm head.
My setup is a mechanical pump from a DI engine already, so...IMO its better fitted to the engine and is more likely to last longer and handle the injection pressures that the TDI engine demands vs. that of the hybrid pump. Plus, in my experience hearing the hybrid pump on my friends TDI Westy Synchro run vs. when we had the 4bt pump on and installed...it was NIGHT and DAY. Just initially off the bat with the smoothness and sound of the motor but then also with the power of the motor too. His drawback was that it smokes a little much for his liking but in a Vanagon part of the problem there is now his intercooler setup is too small for the fueling he has which is soon to be answered with an AWIC setup. I also have many flow improvements as well to the intake system as well as the head which I'm working on as we speak. So...its def. going to be fun!
On a seperate note... the pumps used on Merc 300D's, etc. that I have seen were all Bosch inlines...though, i've heard of a few that were VE rotary. 4bt's came in two varieties as well... the VE and the bosch inline too :) Now what I'd really like to see is the electronic VP44 be fitted to a TDI engine with custom CPU programming and I'd be all over that. The VP44 can handle ALOT more injection pressure vs. that of the VE pumps that were used on the TDI motors.
Joe
Cool, but what are the "cons" to this pump. What kind of shut-down is used and what kind of cold-start assit device (eg; timing adv) does it have?
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dont wanna burst yer bubble,but the vp44 is a piece of crap,at least the ones on isb's,,,ive changed a bunch out ,,, theres all kinds of recalls+bullitens and stuff,,,,id like to try an inline,,but may behard to get the revs out of it,,and oiling ,,and ,a few other problems i can see that would have to be dealt with,,,more power potential in a inline vs. rotary shootout,,,but revs can be a problem,,,,i guess u would call it "plunger"float,,tougher springs can eat up cams,,,, iseen some crazy custom pumps somewhere online,like 10-20k!!!!!!!yea jus a big chunk of billittttt,,sweettttt!!!
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Yes, I am using the Cummins 4bt pump, it is a Bosch VE rotary unit though. Most people doing the mTDI conversion are using non DI specific hybrid pumps. In some cases even, a complete 1.6TD pump turned to the max. in stock form. Others, and a better solution like hillfolk'r is using a hybrid consisting of the IDI TD pump internals and smaller mainshaft with a larger 12mm head.
My setup is a mechanical pump from a DI engine already, so...IMO its better fitted to the engine and is more likely to last longer and handle the injection pressures that the TDI engine demands vs. that of the hybrid pump. Plus, in my experience hearing the hybrid pump on my friends TDI Westy Synchro run vs. when we had the 4bt pump on and installed...it was NIGHT and DAY. Just initially off the bat with the smoothness and sound of the motor but then also with the power of the motor too. His drawback was that it smokes a little much for his liking but in a Vanagon part of the problem there is now his intercooler setup is too small for the fueling he has which is soon to be answered with an AWIC setup. I also have many flow improvements as well to the intake system as well as the head which I'm working on as we speak. So...its def. going to be fun!
On a seperate note... the pumps used on Merc 300D's, etc. that I have seen were all Bosch inlines...though, i've heard of a few that were VE rotary. 4bt's came in two varieties as well... the VE and the bosch inline too :) Now what I'd really like to see is the electronic VP44 be fitted to a TDI engine with custom CPU programming and I'd be all over that. The VP44 can handle ALOT more injection pressure vs. that of the VE pumps that were used on the TDI motors.
Joe
Cool, but what are the "cons" to this pump. What kind of shut-down is used and what kind of cold-start assit device (eg; timing adv) does it have?
I'd really have a hard time of thinking of many cons to the pump. I suppose that to the person that can't find a "hub" from a MKIV style TDI pump to use the adjustable pulley, that would be a con. Initial setup of it (i.e. swapping out the gov. to go to the VW style gov. ) isn't that hard but to someone thats never cracked a pump before...it could be. The pump uses a standard solenoid as well as it has a mechanical shut off if you wanted to rig it up to work. I believe Deo was going to rig his up to use. As far as cold start assist. I'm not going to use mine, going to remove it as this car never sees winter or cold weather where I'd have to worry about it. Mine has a electronic cold start assist. I've seen AAZ pumps with a similar setup. Also...if someone wanted to...the mechanical cold start setup could easily be added to the pump. Other than the initial setup, etc. I can't think of a con for it. Its a DI specific pump, plenty of fully and with the gov. swapped over , etc. it makes the TDI run so nice and smooth with PLENTY of power. There may be some merit looking into adjusting the timing advance springs to match closer to the VW rates, but you also have to take in acct. the head/plunger size as well as other things. Considering though that you can get a new 4bt pump for 500 outright new, 450 rebuilt or 250 used... its the simpliest solution IMO to make the mechanical TDI make the most power it can, yet run smoothly and still have the insurances of knowing you have a pump under the hood that is made to handle what your throwing at it.
dont wanna burst yer bubble,but the vp44 is a piece of crap,at least the ones on isb's,,,ive changed a bunch out ,,, theres all kinds of recalls+bullitens and stuff,,,,id like to try an inline,,but may behard to get the revs out of it,,and oiling ,,and ,a few other problems i can see that would have to be dealt with,,,more power potential in a inline vs. rotary shootout,,,but revs can be a problem,,,,i guess u would call it "plunger"float,,tougher springs can eat up cams,,,, iseen some crazy custom pumps somewhere online,like 10-20k!!!!!!!yea jus a big chunk of billittttt,,sweettttt!!!
Thats too bad to hear. From what I have heard the VP44 has been a great solution and is capable of much higher injection pressures than that of the VE pumps used on the TDI's from the MK3/B4 platform and onto the MKIV's as well prior to PD. Its also what they ran on the latest series of Cummins Ram's wasn't it prior to common rail? Where are the faults? Whats going wrong with the pumps? That is very interesting...
Joe
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The VP44 is a black mark on bosch's otherwise good record. The the most common failure is the rotor seizing to the head and then shearing off the drive plate. On the the dodge cummins engines, pump seizure was often hastened by faulty transfer pumps. It could also happen if the truck was run low or out of fuel. If the fuel pressure dropped below a certain level (2psi?) there was no flow through the pump for cooling, but the engine continued to run fine. The pump would fail in a short time.
The VP44 will not be used on any new designs, according to bosch, so I guess they don't like it either.
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Its a DI specific pump, plenty of fully and with the gov. swapped over , etc. it makes the TDI run so nice and smooth with PLENTY of power. There may be some merit looking into adjusting the timing advance springs to match closer to the VW rates, but you also have to take in acct. the head/plunger size as well as other things. Considering though that you can get a new 4bt pump for 500 outright new, 450 rebuilt or 250 used... its the simpliest solution IMO to make the mechanical TDI make the most power it can, yet run smoothly and still have the insurances of knowing you have a pump under the hood that is made to handle what your throwing at it.
Joe
Wow. It's even a bargain compared to pricing a new or reworked VW VE pump! I'll want the cold-start. Don't know yet if I'll pull it off the road in the winter or not, but my current TD is ugly to start w/o it on the cooler spring and fall mornings. Looks like we're (kinda) close (NH-NY), who are you using for your internal pump work? My local pump shop only does OE spec work :cry: . I can't remember if you mentioned it, but will the 4bt mount on the VW brackets and with what mod's if any?
Thanks
Alain
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hi guys
the VP44 pump was never the problem it was dodge's design for
the electric supply pump.
they had the supply pump suck thru the filter first and then to the
injection pump. this had the adverse result of burning out the
lift pump and then not supplying enough fuel to the injection pump
that would then make the Inj pump work too hard and burn it out.
the solution was to install a new lift pump/fuel filter kit that we sell
and it pushes the fuel thru the system which is much better. also
the secondary filter is a 5 micron filter from Stanadyne.
this fix should solve the problem of burning out the pump.
i've never seen the head seized in that pump by the way.
giles
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well the gov swap and waht not you can do yourself if you are clean and take your time..i did it myself and so did joe...as for the vp44 i think if you have a good fuel transfer pump and your fuel pressure never goes below 5psi ..even under a WOT run (use a fuel pressure gauge) then you'll be ok ..its teh people with out a good transfer pump and with out a guage to make sur eit has fule to cool it that make it a sore problem.. ie only a very limited amount of people actually ahve gauges and read them in there trucks or what ever..think of all the box trucks, ambulances and school buses that have these pumps and the drivers ..first they don't have pyro or boost gauges or fuel pressure gauges to make sure they are in the safe zone for the engine... if everybody had th eright stuff an dwatched it i think the failures would about stop..
later
Deo
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who are you using for your internal pump work
Me, myself, and I ... though, I've had a few pumps opened and modified in the past under my belt myself.
It is cheaper than alot of the worked pumps I've seen around and has many of the benefits that the later series VE pumps had specifically for the DI style motors. Larger shaft, more reinforced housing, correctly matched camplate relative to the pump head/plunger, etc...
The smoothness of the power and the power though... very nice like I said compared to any "hybrid" i've seen. I don't have all the fancy equipment to throw it on the test bench, etc. but it is a fairly simple modification to the pump and doesn't involve messing with shimming or tolerances in the bottom end of it goes. The only ideas we are toying with in the bottom and possibly adjustment of the timing advance springs but it hasn't proven "required" yet. Its hard for me as my pump was up and running on my friends Synchro...but I won't be able to really play with it until its done and in the motor to do all the fine tuning to it. Its going to be def. fun though! With the fuel/boost arrangements and the improvement to flow I've made, along with the AWIC ....oye, i can't wait.
Think i'm going to go work in the basement now
Joe
[/code][/quote]
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Me, myself, and I ... though, I've had a few pumps opened and modified in the past under my belt myself.
It is cheaper than alot of the worked pumps I've seen around and has many of the benefits that the later series VE pumps had specifically for the DI style motors. Larger shaft, more reinforced housing, correctly matched camplate relative to the pump head/plunger, etc...
The smoothness of the power and the power though... very nice like I said compared to any "hybrid" i've seen. I don't have all the fancy equipment to throw it on the test bench, etc. but it is a fairly simple modification to the pump and doesn't involve messing with shimming or tolerances in the bottom end of it goes.
About how many RPM's do you expect out of this pump? I'm thinking that with your piston modifications, that should contribute to some added top end potential but I'm wondering what the pump can handle. I guess at this point nobody really knows. :) I will be VERY interested in hearing how this engine drives once it's all buttoned up.
Brendan
84 Scirocco 8v
00 Camaro L36 M49
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That is the one debate about 12mm pumps... the max rpm's at which they can turn before burning up. I've been doing quite a bit of reading on TDIclub and have heard of guys burning them up, etc. on dailys but then some of the pump heads that people are using as well aren't bosch, aren't shimmed properly (at the plunger) and/or are using the wrong springs to assist the 12mm head.
I will be doing the gov. modification to put the main spring in slight coilbind to extend the rpm range of fueling...however, like you said. Its in the dark as far as "how much" it can handle. Part of the reason why I didn't buy a brand spanking new pump right off the bat too... This one, I can do some experiementing with :)
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aint got time to post about everything,,but giles is right lose lift pump,vp44 is toast,,,istill get them toasted with good lift pumps though(where i work we are a b+c authorized dealer),,lotta school busses+stuff,it sucks changing a vp44 in a bluebird,,what are people all worried about revving the wee out of it???use a diesel for what its made for,,,, torque down in the basement,,,,,,idont see a need to rev my tdi higher than stock,,whats stock redline anyways,,4700 or so??ok let 'er go to 5000,,,,,,i see no reason for 6k and stuff,, iagree, i think testing is needed on my pump,to get the correct advance curve,,,stuff like that,,i dont even have that int.spring removal trick,,iwanna try that,,,,i remember playing once w/ shims in the adv. housing,its sensitive,,i remember once,,more shims,,and on a rev up,while sitting there,it would misfire once or twice up ot max speed,,well,it neded more advance, iwas just checking,,and it seems a few thou makes a big difference,,it doesnt sound rattly like a diesel withtoomuch advance at part throttle and stuff,,,soci bet it could use more advance,,,, i lengthened the exhaust tonite,at least it ends behind me now,,,ends just before rear beam,with a mild turndown,and wrapped where its under the tank,,i advanced static timing also tonite,,that cured the mild cold smoke,that wasnt even bad,it more burned your eyes,than visible smoke,,my static was at .85,,i made it like .98-1 right in there,,,more testing,,,,,the easypart was getting it built,in the car,and running,,now is the hard part,tuning,,sofar im happy with my investment,,
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yeah but i think when you are swapping lift pumps your stille putting them in a sucking position...with my dads truck i mounted the pump back in front of the fuel tank so it pushes and upped the fuel line size to 1/2 inside diameter..then i got rid of the banjo fittings and used straight hose fitting..it doesn't pull the pressure down now. I think if you watch your fuel pressure guage it will last..kinda like if you watch your egt gauge your engine and turbo will last longer..
common blake bump that timing up at least to 1.05 or 1.10..its not a sissy engine...i still don't believe you had it a 0.85 ...damn
later
Deo
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bumped it up to 1 (timing),,,,,now with exhaust,,i hear a li ldiesel,,yea what you did,,way better fuelsetup,,,,,they are$$ but a preporator will give hp,and longer life too,,it removes air before entering the inj.pump.,,,,,hah the boss did a vp44 in a bluebird,,heehee,hope he liked it,,hes about 6 2 250 or so,,,yea he had fun,,,,,i was puttin new head gaskets in a 912,freakin idiots sucked in some caution tape,,whatta mess,,all melted to the cyls,,,drove cyl temps up+poped allthe head seals,well at least 2, but iredid all3 ,,,,pain in the tookus,,, but if heads are resurfaced,,,gotta put ina lead(solder) wire across the piston,bolt on head with norockers,,turnover tdc to crush the lead,,,remove head,measure lead,,,its .039-.050,,,different head gaskets, ranging fromlike .040-.120 in 2-3- thou increments,,theyare always layin in a box too,,unmarked of course,,,,,,it sucks if you gotta do one 3 or 4 times before ya get it right,lol,and we like them around .039,,,,they are surta like a vw aircooled,like metalhead gasket+stuff(for those of you not knowing what a 912 is its a deutz engine,2,3,4,5,6 cyls ive seen,,theyare wired too piston#1 is the f.w. end,,,,,they are air cooled diesel,have individualjugs,,tin all over for cooling air,,,vw's industrialcousin,, i like deutz,,,,i see similarities between vw wheniwork on them,,or its the germanthing,or both,,,,cool lil engines,,be neet to try like a 1012 ina lil s10or somethin,,,oilcooled with cooler integrated on the side,,fan cooled,,,they are neet,when ya have a head off,and look where the "water passages" are,,that isnt water,,thas oil,,,they let oil run thru basically where water jackets would be,,,,,,,,,,,
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A little bit of an update.... ever so inching closer to completion. Waiting on a clutch to arrive next week and for me to finish up the headwork here as its been slow with having to change up the car the motor is going into (found a couple structural problems with the GTD)...but I'm shooting for having the motor ready to drop in by the end of the week. Whether it'll happen next weekend or not...not sure, depends on work, time, etc. as I do rely on the 79 quite a bit for the getting around...
So...some pics....
Here is the 79 I got last fall...currently still sporting its 1.5 NA but doing quite well and is SOOOO solid!
a few before and afters as I transferred all suspension from the GTD to the 79 as well as interior and other goodies to come... including the 10.1 upgrade you'll see in the pics...
Prior to last weekend...
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_1943.jpg)
euro bumpers added from the GTD
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2211.jpg)
and as of last weekend after the GC coilovers and bilsteins were transferred to the front with the 10.1 brake upgrade as well...
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2316.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2322.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2324.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2328.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2335.jpg)
Has a bit of a high stance in the rear at the moment as I'm waiting to transfer the bilsteins for the rear from the GTD until i get my 200mm drums prepped for going on the car so it can be done all at once. I also added the flares, my centra deep dish rims to the mix as well as the poly bushings one can't live without! The car has totally transformed! Just...the 1.5NA isn't pushing much :)
So... onto the motor.
Current status...
bottom end complete, studs installed. Mild port match and polish completed to head for most part and I will reassemble probably tomorrow after i clean a few things up.
Motor as it is now...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2300.jpg)
MK1 diesel modified mount installed...opted for the diesel mount over the gasser unit because of the extra reinforcement and bulk that the diesel mount seems to have vs. the gas one. Plus, i've seen gas ones quite tweaked!
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2299.jpg)
Here is some of what I've had to work with in porting out the G60 intake manifold to accomodate the "D" ports of the TDI. The D ports actually take the manifold out to its limits...if not beyond with the gasket match to the new TDI intake manifold gasket. I've ported out just about as far as I want to go having left myself room to retain the strength of the manifold by keeping a taper to the port which took away alot less material. I still need to finish it, probably an hour or so left in it...but you get the idea. I think for next winters upgrades I'll try and find a SDI manifold or build a homemade manifold using the lower portion of an SDI unit or build up the top of the G60 manifold more to allow more room to port without having to worry about cracking...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2309.jpg)
as it stands now...some more time left in finishing...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2340.jpg)
and finally...the mild port and match on the head...turned out fairly well. not alot more cleanup to do...but def. matched to the gaskets and is so much more smooth without going down and affecting the swirl in the port or the bowl. That'll be next winters project along with more fun!
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2343.jpg)
oh yes...and the TDI valves have been so much fun to clean...had to soak for quite a while in the simple green mixture...ready to go though...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2339.jpg)
So, thats about it for now. Coming along. Will reassemble the head tomorrow more than likely and finishing the intake manifold as well as matching the exhaust manifold. Button top end of engine and finish detailing the pump now that my gov. setup is complete...
In a few weeks....hopefully barking to life!
Joe
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Man those early Mk1's wake right up with just a few external mod's. You need to find a Euro GTD grill with the 4" round driving lights to complete the look of a euro GTD! Nice! ( I know a guy here in NH that has a complete one w/all the lights and the core support, but he wants $400 for it, ouch!) I wondered about how the TDI "D" ports would match up to the earlier manifolds. This confirms it, man those top corners get REALLY thin, dont they? What other options do we have besides tring to source an SDI manifold from the other side of the pond? Wicked nice work so far!
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Thanx for the comps...
Your right...very little clean up the MK1's. Though, just the other day now i found an MK2 jetta coupe sitting down the road (gas) that a guy wants $400 OBO for... I'm tempted (just thinking about how the rabbit will handle the power of the TDI) but can't bring myself to go away from MK1. It did clean up quite nicely and its kinda rewarding for it too. Found it for $100 last fall...brought it home, fixed the brake lines, replaced a few odds and ends as well as the alternator with one i got from Jake and it has treated me great all winter long, 140miles per day and still getting around 41mpg. Just isn't that fast :)
I plan to keep it and redo it in its OEM color here next winter unless the ideal 2 door comes my way... i only seem to have luck finding nice 4 doors though. Doesn't look it from the outside but where it counts, down in under, etc. this one is almost flawless...
As far as manifold choices....with the D port they are few and far in between. You can go with the TDI or AAZ intake manifolds as they all have D ports. Alot of guys with TDI daily drivers upgrade to the PD130/150 intake manifold which is slightly larger but is still a very short runner unit. You could always hack and plenum a TDI or AAZ manifold, but still you have the sharp turn at the bottom which doesn't represent alot of benefits in the first place and then there is the task of lengthing the runners of it ....
Now, as far as counterflow manifolds the G60 and the MK1 GTI one (or CIS units for that matter) are on the correct inlet side for what I was looking for but the amount of material that can be removed from the manifold to accomodate the D ports is pretty much the same. I don't have a Fox manifold or a Audi 5k manifold (which you'd have to chop the extra runner off of ) to compare too...but I imagine they are similar as well. Supposedly of the counterflow manifolds the G60 unit and the audi 5k flow the best. My thoughts were that maybe next winter I'd build up the top portion of the manifold with and aluminum weld, smooth it back out...plane the gasket surface and further port it out to the D shape. Its pretty damn close now though, and probably as far as I'll go. The taper I did in the port keeps the strength of the manifold intact without distorting the shape of the runner too much and still gets the "d" port in there for the most part. We'll see how it runs...
Ulimately...I'd like to find a lower portion of an SDI unit or the early entire 1 piece SDI manifold (like Simon used on his motor orginally www.centralvwaudi.com i believe). D ports stock. The advantage with the 2 piece one would be that you could add your own custom plenum to the top rather easily...or, a thought that I had pieced previously but just couldn't see spending the $250 for the lower part just for experiementing was modifying the lower portion of the 2 pc. SDI intake manifold to a MKIV style 2.0 crossflow upper portion. I suspect that clearances with the injection pump LDA on mTDI's could occur there though.
So for now...thats what I have and am running :)
Joe
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i should have snapped a pic of my modified tdi intake while it was apart,,,,i cut off the intake about 1 inch of the manifold,just enough to connect a hose,than massivly ported it and smoothed it out,,you may be able to see it in the blowup pics i posted,,i never liked the 90 bend on the stock 1.6td intakes bolt on stub ,too much of a choker, it can be improved....
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Thanx for the comps...
As far as manifold choices....
I don't have a Fox manifold or a Audi 5k manifold (which you'd have to chop the extra runner off of ) to compare too...but I imagine they are similar as well. Supposedly of the counterflow manifolds the G60 unit and the audi 5k flow the best.
Joe
I've got (still in the cars) manifolds from a Mk2 (Golf) 8v CIS-E and a (Audi) 2.3 5 cyl CIS from an '88 Quantum. I don't think i could use the Mk2 in my Q, the plenum is angled toward the driver's side, which would put it into my battery-shelf. But by just looking at the 5 cyl manifold, it does look bigger in the runner diameter and another "pro" to the 5 cyl one, it's got the cold-start assist injector in the plenum :!: . How perfect is that set-up for water-meth injection :D :twisted: ?!!
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sweet,hey update, i have been tuning the water injection,,my egt was going up slightly using straight blue washer fluid,ive been cutting that 50-50 with water..now it cools down the egt now, like they say it does,and i still feel it kick in.. feels the same power wise..i bet thats what took out the turbo,excess heat,and overspeeding it to the moon!!theres tons of meat to take out of those tdi intakes isnt there??i saw the pic,basically it looks like what i did,i took out a bunch above the port in the intake,and made the ramp into the port(in the intake)bigger/smoother to match up to the port,,basically,you want a "port" sized/shaped hole all the way up the manifold runner,look in an intake,its better to see what i mean,it looks good man!!!get 'er goin! you are gonna love it!!!
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Hey I just had a brain storm :o (EVERYONE DUCK!! :shock: :shock: )
:?: Couldn't you re-index the mounting holes a little lower on the non-TDI manifold flanges by either "oval-ing" them on a drill-press and fab in a couple of locating pins with corresponding receivers in the head (or if your really good... I'm not) filling them in and re-drilling them lower to equal out, top AND bottom, the material removed for port-matching? 8) :?:
If this sounds good, how much do the mounting holes need to move? :wink:
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Good thought... but with the amount of material that has to be removed from the non-TDI counterflow manifold (in my case, the Corrado G60 one) it would be as thin at one end as the other...it could be possible to center the manifold a bit more by doing eccentrics, even out the amount of material from both the top side and the bottom side instead of taking more from one area but then you'd almost need some sort of spacer or bushing IMO to keep the manifold from moving on the port with the vibration of the diesel motor and just the heating/cooling cycles of the motor. Its a thought though...could work.
There is def. alot of material on the 8v and 5 cyl counterflow manifolds...however, not quite enough where needed at top as I mentioned above. Its going to get out there, but we'll see how it does. I think I'll still build up the top portion next winter and plane it back out to really make things nice :)
It'll be done soon. I have lots of new pics and the motor is pretty much done. Had to ditch the t belt backing plate for using the MKIV style adjustable pulley but everything else has come together pretty nicely and the motor is pretty much out of the 79 ready to swap in the TDI. It'll be most impressive :) Just working on the details at this point before swapping in.
Joe
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...it could be possible to center the manifold a bit more by doing eccentrics, even out the amount of material from both the top side and the bottom side instead of taking more from one area but then you'd almost need some sort of spacer or bushing IMO to keep the manifold from moving on the port with the vibration of the diesel motor and just the heating/cooling cycles of the motor.
Joe
That's why I suggested fab-ing locating pins, possibly three of them. Wouldn't they address this?
Can't wait to see the rest! You're almost there!!
Alain
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Its begun...the old 1.5 is almost out of the 79...haven't had time to get the pesky exhaust bolt holding the motor in at the moment yet this week as my 72 Westy kinda had to take over commuter duty and its not gas friendly so I've been biking to work and staying over in the area between shifts...hoping to get the TDI in at least this weekend...
But....some pics of progress... thought I had a few of my 4 hr ripping session over the weekend of removing the old motor, but appears I only took one of the car...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2381.jpg)
Finishing the head...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2352.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2351.jpg)
Found a helper at work that loves to work on motors who helped hand lap in the valves again and installed the cam and lifters ...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2361.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2352.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2358.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2363.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2362.jpg)
Head installed...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2377.jpg)
The nozzles for now until Race 520's come into my budget...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2378.jpg) thanks to Karl...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2375.jpg)
Marking and aligning the MKIV style adjustable inection pump pulley hub and setting initial timing marks for easy reference down the road...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2368.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2371.jpg)
Attempt to work with the timing belt backing plate so I could use the upper cover. It worked, modfied, fit, etc. However, once the hub was pressed to the pump and the pump pulley installed and tightened...the assembly rubbed...so scratched the upper timing belt cover and backing plate...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2382.jpg)
Current status of engine...almost ready, only a few things to do and install the exhaust manifold w/ turbo (retapped for larger studs) as well as the intake manifold once in the car.
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2386.jpg)
The MKIV injection pump pulley will be so sweet. It adjusts very easily and will make "on the fly" timing advance/retard a snap with the dial indicator.
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2385.jpg)
Thats all for now...
Joe
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Nice seeing progress :)
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Very Nice!
How tight do you have to tie the wife up to get your parts on the kitchen counter?!! LOL !!
Alain
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Well...fiancee... close enough though.
She is actually very accomodating to it, as long as I clean up my mess. Though, the suggestion has been made to get a part washer for the basement.
Should've seen the bathtub last fall when I first cleaned the cylinder head...that was fun...
Joe[/quote]
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mine does get a little testy when i wash parts in the dishwasher,like consoles,etc,but hey,it works awesome,its like a hot tank in your kitchen!!! :shock:
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Sorry folks, I tempted fate 20 yrs ago and I got a 5'2"- red-headed- irish-italian- French- cherokee- german- woman to show for it :shock: :shock: !! I KNOW my limits (now) :roll: !!
Alain
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More progress...the old 1.5 is out in the mTDI is sitting in the engine bay. Decided that I needed a day off yesterday and just stayed home, took the sick time and made major progress on things with the mTDI. I had alot of debating to do about the engine compartment, whether to paint it or not since the car is going in this winter for a complete paintjob, etc. in the original Inari color. I couldn't see painting up the engine bay for about 5 months of driving and the work involved in removing all the paint after...so, i gave it a good cleaning and went with that.
As far as transmission selection, I had a few here to chose from. I've got a 4 speed GC, an FN from the GTD, an FO which is the one that was on the 1.5 that I just pulled as well as a 2y 16v tranny. I decided to use the FN because it was in the GTD and if anything it is the one that would "go" first as far as grenading. The FO must have been very lightly used as it shifts like a dream and I'd like to use it as part of a base for the tranny I'll be building this winter to better suit the car since an LSD, etc. wasn't in the works $$$ wise this year. It'll be the FO gearset with a 3.67 final from the 2y with all new syncs, gaskets, LSD, etc. I didn't detail the tranny either...once again, couldn't see the sense in it when it could go or just be removed come fall again.
So....some pictures... the motor is sitting in the bay now waiting for everything to be hooked up. I'm waiting for an inlet weld flange to come for the T3 that I can use as a spacer as I was having a slight issue when fitting everything together with the ATP manifold and the G60 intake manifold hitting the compressor housing on the turbo once mounted. The spacer flange will give me the clearance I need. It seems that accounting for the fact when I did the GTD with the IDI TD before and its downpipe and knowing I wanted to go TDI in the future paid off as the downpipe fits perfectly to the slightly taller block, etc. Hooking everything up, etc. shouldn't take too long now and I look to maybe here it run this weekend possibly depending on when that flange gets here, and the weather which isn't looking too great...
So... last weekend...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2388.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2389.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2390.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2391.jpg)
Yesterday... and don't worry, that FRAM filter is only on there to keep it on there for the initial start/warmup...then I'll be changing the oil right away and moving to my Mann filter and Amsoil =)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2392.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2393.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2394.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2395.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2396.jpg)
Its a weird feeling that the motor isn't going into the GTD but it'll be nice to have the feel back. Never intended on the 79 being so rock solid and that it would be receiving this as it first started out a easy transpo solution for $100 last fall...
Joe
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Actually, if you've seen the video of that insane Finnish Mk1 '77 gasser, you'll probably be enjoying nearly the same "OMFG" responses! Early Mk1's are hard to come by now. To have one with a$$-kicking super-powers brings it to a new level. Nice going so far!
Man, THAT car IS clean!! Just a little skin cancer around the battery tray and rad support! That's awesome considering our climes!!
Alain
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More progress...if things keep moving I might be able to start it for the first time tomorrow... that'd be nice.
Got quite a bit done here today... started to ran so I had to come inside for now...
So...here we go...
Finished G60 intake manifold with modified boost return section to serve as inlet...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2397.jpg)
Installed...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2400.jpg)
Preparing this summer's Snail for action... next it'll be a holset !
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2398.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2399.jpg)
Installed w/ boost return on intake manifold as well as oil return line...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2401.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2403.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2404.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2402.jpg)
Looks like its going to clear up...out to do some more...
Joe
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Its' AlIvE.....IT'S ALIVE!!!
Yeap, I got it running this weekend. Only for a really short burst and it took forever to get the fuel system primed but it did come to life yesterday...no exhaust, no intake plumbing, etc. So I need to work on solutions there before I can start it and let it go on its own to warmup, etc. It was exiting to hear it start though :)
Joe
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(http://www.imagestation.com/picture/sraid187/pcc182f18173f0bc354171b3e6dc96951/f2473423.jpg)
Giggity-Giggity! :D
When will we have a video?
I'm really anxious to hear how it runs once everything is all broken in!
Brendan
84 Scirocco 8v
00 Camaro L36 M49
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yea good deal!!!!!!!,,,,wait till you drive it!! it aint no lil na,,itll run!!!!! i dont know the deal,but mine took for ever to prime,and ive got the pump(lift),,,i had to keep all the lines loose,and tighten like 2 at a time,,i tightened 2 down,,and was cranking it more to prime the other 2,and it started !! so i went with it,and tightened the lines down,,but it ran on 2 cyls,till i recracked those 2 lines loose,then it cleared right up,,,,,,and it seems like anytime you have a line loose,for service,etc,it seems to take some time to get that air out again before it starts hittin on all cyls.........
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Hey, where did you source your oil feed and return lines? I need some customs for my TDI project.
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It's ALIVE !!!
Awesome job Joe!
Alain
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I'm sure there's some love in that engine with those ceramic-coated pistons. :D
I would be interested to hear of your honest appraisal of the smoke from the engine at full load when you get the fuelling and everything sorted out and the engine broken in. :)
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Thanks...I'll def. post more info on once its up and running on its own, smoothly, with exhaust, etc. This weekend I'm hoping to really get things together and that. Taking the downpipe with me today for the mods it needs. I appreciate the interest and comments though. I am especially interested in seeing how the machined pistons work out with the lowered CR to run more boost and fuel coupled with the ceramic coating. I know there is ALOT of fun to be had here...
As for my oil feed and return. The flanges are billet aluminum and bolt to the center section of the turbo. Same as what I used on my IDI TD setup when I had it. The feed line is a SS braided line from atp if I remember correctly and the return line is one that I made using Aeroquip fittings (and a metric/AN adaptor to get it into the block) along with their socketless hose. Makes for a very clean setup...
Joe
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Joe its been like a month since you updated us... What's rockin?
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She is up and running...have been busy and working out side so I haven't been posting much. Just working on finishing up the dp modifications and getting plumbing for the exhaust sorted. Starts and runs awesome though....the pump is GREAT. Had to make a few other modifications to the cummins unit but its working perfectly now.
Maybe a bit more time to update here later in the week.
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Has your pump been tweaked at all or is it basically a stock Cummins unit? I cant remember. :P Thanks!
Brendan
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Its a modified cummins pump unit... 12mm, DI specific, with VW gov. bits and a few other things I did...
Other than the modifications I made and "tweaking" the LDA for settings, etc... its the plain cummins pump. No really any need to "tweak" it beyond there as I have all the fuel I'd ever need. Could be a gov. mod in the future but with the 12mm head I may stick with the stock VW gov. springs without shimming to keep the 12mm head happy.
The pump swap of course won't work with just a straight swap as the 4bt uses a different style gov, but mine is working great now that its up and running :)
Joe
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Figured I'd go ahead and bump this up... Just drove the car today probably for the last time as its time to say goodbye for winter and hello for upgrades.
Fuslit picked up the GTD, so now I have room in the garage and we'll be workin back and forth with each other...but a few pics...
After bringing it back a couple weeks ago when it finally got inspected...go figure, the one day we had snow!
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2757.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2762.jpg)
Damn NYS stickers don't stick at ALL! nor do the registrations... also...anyone have a rabbit windshield around? The one in the car is starting to fog pretty bad...though adds to that "ratty" look it has at the moment...
Beauty shot...of course, ready to see some very more interesting things this winter!
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2755.jpg)
Finally a spot in the garage and knowledge that the GTD has a good home!
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2750.jpg)
And shameless plugs of the other cars :)
The bus...
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2765.jpg)
The B3...receiving a mTDI in the near future I hope...that is after the wedding and grad school this year...
(http://i18.photobucket.com/albums/b109/joeallison_99/Passat%20Wagon/100_2745-1.jpg)
So whats in store for this winter?
-AWIC install finally. Using a very nice exchanger I have located utilizing a VR6 auxilary radiator, a large water pump, res. located in the hatch and aluminum plumbing...
-possible install of the AAZ non turbo intake manifold...have it...just need to see if it will clear my turbo mounting, etc. and work plumbing wise...
-check flow between G60 modified intake manifold, AAZ unit and a PD unit
-Installation of R520's to really make things interesting...
-fuel cooler install
-few additions to the cummins pump
-possible turbo upgrade
Thats what I have on my list... paint and bodywork is the hope too...wanted to have a older VW caravan away from the wedding in july...but the rabbit needs some beauty work prior... bus...rabbit....bus....rabbit... already have the busses and rabbits rounded up...just not mine with paint yet...
So...more to come...detailed pics of the installation components for the AWIC setup, fuel cooler, and also hopefully front end reinforcement for the front core support. Somewhere in there is the idea of a built transaxle...or a cable shift swap...but don't know where that all fits in the budget...
Looking forward to a winter of progress though!
Joe
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HAPPY NEW YEAR! Hopefully great things to happen this year!
Joe
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if t his has already been answered then forget it, but what turbo and manifold are you running? and what intake hose is that?
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Bringing this one up! :) Joe, would you mind expanding on your tach system? You are using the stock cluster, correct, with an optical setup? I would love to know more about this. Thanks!
Brendan
84 Scirocco 8v <--- TDI swap underway
01 Jeep TJ 4.0
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Ok, so...I've had quite a few requests here in the last month to "update" my thread. I've done alot of random PM'in, etc. to those interested in where the project is...but I thought I'd do an update.
The mTDI is up and running again for spring here...bigger and better thanks to some pump mods that Named Tin Tin did additionally to my custom 4bt injection pump setup. He is a great guy and really awesome to work with! Can't say enough good things...
I'm still chasing a little bit of a weird starting problem, very intermitent, def. with the pump solenoid I think I tested the solenoid, and it doesn't seem to stick ,etc. out of the pump...however, I have a theory that maybe when the key is intially turned on that there is too much of a draw on the battery (at start I'm pulling the starter, my holley "red" fuel pump which is pulling power right off the solenoid location). Flick the key a few times...instant start, sometimes go out in the morning, turn over without glows INSTANT start...then, shut down, and its a bit of a pain again. Def. am getting power to the solenoid as the pump is going as well (the fuel pump), but I'm wondering on crank whether the solenoid doesn't get enough power. Just a theory...kinda like my thoughts on the solenoid when I mentioned it in the "Troubleshooting" section if you are interested in reading with my first attempt to test it with a battery charger...
Another though is possibly something with the fuel pump and/or the fuel filter itself... working on that...tracking it down... its very intermitent.
Anyways...that was long winded...
So here is the car as it sat yesterday with the host of VWs here at the house!
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3009.jpg)
I traded off the Centra Typ 11's I was running for a set of pretty rare ATS Cup "White Edition" rims (15x7, ET28) which I really like better on the car and such. Just found on this board that Audi80 is the first person I've found so far besides myself with the same set of rims! Trying to find center caps for them now and the tire shop buggered one of them when the tires were mounted too...so, they'll be paying for that... its not huge, but enough to piss me off...
The rims on the car...
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3010.jpg)
and a shameless plug of my baywindow westy since my driveway was all "oldschool" yesterday! Looked like a flash out of the 70's, early 80's with the cars there...
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3012.jpg)
So...what am I working on now? Where am I at... well, still no R520's! Did I mention I'm getting married this summer!!! So $$$ is in short supply and R520's are quite the dive at the moment. I'm working on it though... but currently the .216's in the stock 1z/AHU bodies (190bar?) which really need to be reshimmed, especially when going to the R520's here...
(so...if anyone knows of a good deal on injectors and reshim....let me know :) best price I've found around here is 35-40.00 /injector for reshim + the nozzles)
But...most immediately, I'm working on getting my AWIC installed.
so...my system...
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3028.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3027-1.jpg)
Old Hamm's Brewing Company 2.5 gal aluminum keg (for resevoir)
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3029.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3030.jpg)
The other parts of the setup consists of a intercooler that a friend and i had made back when I had my Lysholm Stg 4 Corrado...
A VR6 auxilary radiator for the heat exchanger (all aluminum)
Large electric water pump (RV/Hi flow/low amp draw)
I had to go "different" with the res on the AWIC as I didn't want the car to be too racey and I'm trying to do "original" and different things with it keeping to a time period sort of thing. Hard to explain, but its all right in my head :)
So, thats within the next two weeks here (and a fuel cooler i have to install too). The intercooler will be mounted in the battery location under the hood (battery relocation done last fall), and then in the trunk the battery will be moved from the spare tire well to the d side or p side area of the trunk on the flat portion right above where the bumper bolts are... on the opposite side, the keg will be mounted on its side to help balance the weight when full of water/methanol mix (gal of water weighs about 8.6 lbs from what I have found... so 2.5 gal, will weight close to 20 lbs) , the pump will also be mounted in this location as well.
Still need to put in the tach setup as well. Debating on whether to convert the stock vintage style "round" tach to work with the W terminal or use my optical setup. I'm leaning towards the W terminal setup because its one wire and "less" in the engine compartment. Also, since I run serp belt I feel there is less chance for slippage to worry about compared to if I was running the W setup on a V belt car...
Hmm...that'll be close to it before the wedding here. I have to install my autotech upper strut bar here after the intercooler install and I may relocate the fuel pump to the back of the car more instead of right up from...we'll see. May even go to a smaller pump (Facet) and use the Holley Red pump in the baywindow to feed the Dellorto carbs I have on that particular motor.
I had a 02a TDI trans lined up, but it sold...I'm still not completely sure what I want to do there this winter, but it will either be a seriously built 020 or a 02a conversion... LSD, hardened gears, etc. etc. Something will have to happen. Hmm...that, bodywork and chassis reinforement too. And maybe even a Holset :)
The car is so much fun to drive though...its a bit on the crazy side and with the diesel trans it really you can tell could use some other gearing. First is useless as you end up shifting as soon as you push the go pedal...too much pedal and its just tires spinning....
Think thats enough for now...thats a long post...
Joe
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Sounds like quite a bit has gone on since it was on the road last winter!
I still haven't gotten my ride in it. At least I get to say I have heard it run (however briefly)
Looking good man.
-Todd
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Re your gearbox ratio; would the clusters out of a Quantum/Audi 5 ganger fit? That'll give you 1st like your 2nd... 4th like your 5th and a 5th with a ratio of 0.53 to 1 :mrgreen:
This is something I have never researched as I never seem to have a 5 ganger at the same time as my 4 ganger TD's. Killed off my last one when I bought my 1st TD
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Very nice ride man :D I'm sure even with just the .216's in there that car must boot. I wanted to mention something to you about your A/W IC setup, that rad you have looks abit too small to run on your setup. A good rule of thumb is your rad should 2 times the displacement of your IC. A buddy of mine just did a A/W on his 16vT and his first rad was twice the displacement of his IC, and that turned out not being big enough, he ended up having to upgrade to an aftermarket honda aluminum rad(almost 4 times the displacement now) in order to get proper cooling efficiency.
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I appreciate the comments...
On the AWIC heat exchanger. The picture is deceiving as to the size of the VR6 auxilary radiator that I am using. Also, when looking at a properly designed AWIC setup, there is alot more than the "size of the exchanger" to consider. I've never read the rule of thumb where the exchanger needs to be twice the size of the intercooler itself.
Corky Bell in Maximum Boost also states that the front cooler is the least important part of the system.
If you think about it, the exchanger does most of its work when the car is sitting at idle, not under boost helping to dissipate any heat soaking that may occur at idle.
The amount of time that water spends in the front cooler vs. the amount of heat there doesn't present a big enough trade off to install a larger front exchanger (especially when I start running out of room to put stuff in an MK1). Also there is to consider the size of my res. (2.5gal or so), the capacity that the hose will carry from the trunk of the car to the front, plus the capacity of the intercooler and the front cooler itself.
The res. actually is the most important part of the AWIC system besides the core/intercooler itself. Bell's book also states that for a 15 second "heavy" boost run that a pump capable of 10gal/min will move 2.5 gal of water in 15 sec.
Great mass of water = greater the thermal inertia
All total...I should have close to 5gal of water or so that I'll be moving around between the 2.5 gal res. and the rest of the system capacity.
(And if I want to ice it...i can throw the keg on ice...and Wa la!)
I've put alot of work into the AWIC setup in the last year. Changing through a few different pumps, had a series of heater cores i was going to run at one point, etc. and have wanted to have this installed for quite some time. It'll be exciting to get it in.
You friends 16vT will run hotter than the mTDI i imagine and what was your friend using for a res, where is it mounted? What was the total amount of water capacity in his system, and what was he using for an exchanger. There are so many variables to consider, but I'm happy with the design and will see via intake monitoring just how efficient it is once hooked up...
I'd be interested in the whole picture with the thought that you discussed and more info on where it came from to weigh in the future but I've never heard of making the cooler that much larger unless your res. is under the hood and/or the total h20 capacity of the system is low/contained under the hood.
Joe
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His res was located in the hatch, and his pump is 15gal/min, and a 3 gallon res, but my point was reagardless of sump capcity, if the rad is too small, it won't be able to cool the fluid fast enough, therefore resulting in a static temp increase across the board. Now another key factor to consider is turbo charger efficiency. My friends 16vT is running a gt3037R @20psi, @20 psi this turbo is making alot of heat. The original rad wasn't heat soaking but the overall static temp was too high for his liking.
Now if you ran a gt20 or a gt22, where the efficiencys are stellar, your cooling requirment is reduced. I run a GT20 @22lbs on my MK3 with the stock intercooler, and I haven't had any heatsoake problems. I did 4 consecutive hard runs with my car, on a warm day, while logging intake temps through VAG-COM, and at the end I only saw a 5 degree temp increase.
Which turbo are you running again??
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Well, I guess we'll see. If I'm proven otherwise, I'll run two in a series :)
My turbo is a standard T3 unit, nothing fancy...can't afford a GT series at this moment and probably will go to a Holset this winter. I find that interesting...makes you wonder what...if any good one of those PWR cannon AWIC do anything at all...
Hmm...
Joe
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FINALLY... no more trips to the welding shop...
Added this to the arsenal today thanks to Todd (Fuslit) and I poking around on Craigslist. Couldn't pass it up for the price, so I drove up to Rochester this afternoon to make sure it could be mine!
After that...found he also is selling a TIG machine (500.00) as well as a pretty nice portable plasma cutter too (800.00) and he only sold this because he upgraded to a 220v MIG unit.
Now just have to get some gas bottles and get to it.
(http://i18.photobucket.com/albums/b109/joeallison_99/Misc/100_3034.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/Misc/100_3037.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/Misc/100_3035.jpg)
Joe
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Did some more work today on the car.
Namely... I was able to mount the AWIC finally, the "keg" res. and the pump in the back of the car. I'm pretty happy with the mounting of the intercooler and how I ended up doing it just in case I ever wanted to return the car to stock and/or run a battery up front again.
A few pics...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3043.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3041.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3040.jpg)
Tomorrow...may remount my aux. oil cooler slightly to make some more room up front for the AWIC radiator and the fuel cooler (though, may run that lower in the car, or up in the wheel well...haven't decided yet. Finding room in the MK1 body is getting harder to do.
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3044.jpg)
Decided to cut costs and save a bit this summer by not going for full aluminum intercooler pipes at this moment. Plus, I have quite a few full mandrel aluminized steel piping downstairs that is just sitting and could be used...not to mention, good first practice for the welder as well. Have a variety of angles to use as well (one 135, several 90's and 45's). Going to order what silicone adaptors I need tomorrow online probably and if all goes well...maybe have this up, in and going sooner than I thought!
Going to work on the wiring/relay setup for the system tomorrow as well I think...
Anyone know "the best place" to buy the silicone couplers and elbows? I was looking at summit... and Ebay.
Joe
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Joe, I got something for you :D
(http://www.kotinet.com/matti.farm/Myydaan/IMG_2563.jpg)
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WAHOO!!!!
:lol: Kudos man!!! Thats Awesome!!! :lol:
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Well...more updates... A few of the pics are about a week old now as I went about installing the fuel cooler, relocating the oil cooler slightly and installing a few of the AWIC components...
The fuel cooler I'm using...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3047-1.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3048.jpg)
Also...the AWIC heat exchanger...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3051.jpg)
Some of the biggest good stuff came tonight though... my mocked up intercooler tubing/routing with the silicone connectors (that finally came today...after being a week late!)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3060.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3061.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3063.jpg)
Deburred, cleaned and flushed everything out of the intercooler system tonight. Drying now and I'll permenently install the intercooler tubes, etc. tomorrow. My autotech strut bar I believe is going to have issue clearing the tubing. Have to slightly "re route" the vac. pump line from the booster as well, but thats not a big deal at all. I'm very happy with the routing of the piping and its length.
The bay also doesn't look too cluttered in my opinion either. Can't wait to see how nice it is once the paint/bodywork is done this fall/winter.
Good news on the drivetrain end as well. Will be getting a CTN trans this weekend for sure in trade for another 02a that I sourced for someone.
Very exciting
Joe
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Dang - NICE ride, man.
Beers,
Matt
\x/ hillfolk!
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Some more progress...
boost tubes fully installed after some tight work, etc. No rubs, etc from what I can see and I really took it for a run today and it was holding 30psi without issue...could have gone more...but, no water system yet..
Going to work on that setup here tomorrow afternoon and Monday...electrical setup, etc. and maybe have the water all set up for Weds.
Only thing that didn't work was I was hoping to use a stock overflow tank for the "fill" point in the system...since the keg is in the trunk and the pump which are the lowest points... Having it up high would make filling and bleeding easy...so, think I might get a nice small aluminum overflow tank and call it a day. Doesn't have to be huge.
The system is going to be really efficient though...so far I'm calculating 5 gal of water or so..., very nicely sized res., good line and heat exchanger flow, etc. :)
Now...if only R520s were in the budget...
Will have another goodie to post tomorrow I'm sure, but for now...
Intercooler plumbing in and installed and I did it JUST right as the autotech strut bar I've been waiting to put in just clears things!!!!
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3064.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3065.jpg)(http://http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3066.jpg)
Big reason for the fit is having moved place where I am pulling the boost reading from, which was the inlet source on the intake manifold...but now is on the intercooler since I had it there ready to use!
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3067.jpg)
going to get a nice stainless one down the road...hate the vinyl tubing, but want to be "happy" with "where" things are located before I invest money in more expensive "odds and ends".
By the way...if anyone wants a phantom series vac/boost gauge (reads 30Hg/30PSI split), let me know. I have no use for the vac. side and would love to get just a boost gauge instead of the split...don't know what I was thinking in the first place...
Thats the update for today!
Joe
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beautifull. You have no idea how much this build has helped me with getting my build rolling.
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Thanx :)
Another goodie for the MK1 as of today which will be going in this fall/winter.
02a TDI tranny... Code "CTN"
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3069.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3068.jpg)
and these goodies on the way from Finland...
(http://www.kotinet.com/matti.farm/Myydaan/IMG_2564.jpg)
(http://www.kotinet.com/matti.farm/Myydaan/IMG_2563.jpg)
The "white" ATS caps were hard to find but are the correct ones for the "White Editions" that are on the rabbit.
:)
Traded this 129k 16v 02a trans that I bought and pulled last week for the trade...as well as a shift box
(http://i18.photobucket.com/albums/b109/joeallison_99/VW%20Stuff%20for%20sale/100_3052.jpg)
working on cleaning up the CTN trans now to hopefully make it look close to as nice. However, depending on $$$ I may do an LSD this winter for it, so I'd be taking the case apart...maybe powder coat. Def. will 'blast the case though and do some other work! Going to be great gearing for my particular setup though...
CTN
1st 3.778
2nd 2.118
3rd 1.360
4th 1.029
5th 0.755
R&P 3.157
Right now with the FN in there, its really interesting with the R&P. Can't wait to have this stuff in!!!
Joe
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Hmm, does Matti have more of those clutch cable kits? :D
This is looking great! The tubing is top notch, not cluttered or cobbled in any way.
30 PSI? You're using a T3 from a 1.6 right now? Damn! I also have a T3 and was planning on using it as my "Shakedown" turbo until I get my final setup worked out, but maybe not! :P Plus, I've started pulling apart the T3 for a quick rebuild, but I snapped three bolts on the turbine side and I cannot get the turbine side separated from the center section. My wastegate valve is also bent and hopefully a machine shop can straighten it as it seems finding a replacement is near impossible.
Looks great Joe, very inspiring. :)
Brendan
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LOL , I don't think so...but it could be asked.
On the turbo. I'm not running a stock t3 from a 1.6 TD. Its larger on the exhaust side, a .48A/R at the moment with a .42 50 trim compressor. Its not what I ideally "want" on the car...but we're working on that for this winter as well.
Joe
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Nice job on the install :D Quick question for you, your breather hose off the valve cover, where(or what) did you run it into??? mines sorta sitting behind the engine and i get that horrible oil vapour smell that makes its way into the car(I'm an mk3 fwiw) at times.
PS that CTN tranny is gonna make that little bunny fly :D
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Thanks for the comments...now I need nozzles and I may have an excuse as I think these ones are on their way out the door...so to speak.
Anyways...unlike alot of people I've seen that have vented the breather/ccv to the atmosphere, I still have mine plumbed to the intake tube.
Yah...can't wait to get the CTN in...the FN is really limiting in what I can use of the power band...and boost, especially in 1st and 2nd.
Joe
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Hmm, does Matti have more of those clutch cable kits? :D
:lol: I could get a couple more :lol:
Hey Joe, what car are those shifters from? I have a Passat shifter in Scirocco and the cables are a bit too long :? I was thinking if Golf or Corrado cables are same length?
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LOL , I don't think so...but it could be asked.
On the turbo. I'm not running a stock t3 from a 1.6 TD. Its larger on the exhaust side, a .48A/R at the moment with a .42 50 trim compressor. Its not what I ideally "want" on the car...but we're working on that for this winter as well.
Joe
hey joe,hows the response on that turbo????im tryin to figure out a new one for my setup
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Matti,
Oh no...I may have inadvertantly gotten you into a business Matti! So nice though that I'm not going to have to run the damn hydraulic clutch setup. Its not the fabbing involved with the system...its just the idea of the wet clutch...i dislike. I may convert the b3 to cable clutch as well in the future here...hmm, maybe I should have gotten another! Anyways...
Matti, particular box is from a MKIII VR6 GTI. The box itself is slightly more "slender" in design, slightly shorter and is more curved towards the back compared to the 'rado or passat boxes. However...I thought about cable length as you were saying and sat my very nice passat cable shift box I have here for my swap next to the MKIII GTI one....no difference in cable length from what I can discern. I've heard in the MKI the best way to solve this problem (of the cables being too long), or rather, the best install and what I intend to do is to mount the cable shift box TOP SIDE on the shift tunnel and run the cables through the firewall vs. expanding the existing opening and mounting it up through the bottom.
hillfolk,
On the turbo. I'm working on getting a tachometer setup in the car, I really need to get it in to see where the turbo is spooling up, etc. My optical tach setup is having issues, so I think I'm just going to go with the Dakota Digital convertor (was going to try the tach conversion, but can't find the right electrical components). My impressions...well, mind you...I still have .216's in the car and the FN tranny which essential doesn't allow anything to get going in 1st or 2nd just because of the gearing...However, the turbo does respond quite nicely I think and I've had it up sustaining 30psi here. I haven't run it out because I don't have the water system installed yet for the intercooler, but that should happen today/tomorrow. With R520's and the low end fueling I can pull from them with the pump setup, I'd expect it to be ALOT more impressive. The turbo itself was used, so I may need to rebuild it this winter but overall I'm happy with things. Though...there have been GT units I've been considering and possibly a holset...but doesn't sound like that is working well for you. I think there are merits with a slightly larger cold side (say .50 A/R, .53) and the .48 turbine side. However, it does effect spooling...but top end response is better with the larger turbine side A/R. Fueling makes a big diff though too. It'd be nice to find something like a .53 A/R cold side and a .42 A/R hot side honestly. It keeps the "smaller" turbine side in check for quicker spooling, but gives more top end breathing (more so than the .36/.38 stock IDI TD T3 units) but doesn't take it too large to hurt low end spooling depending on your fueling.
Joe
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i dont wanna jack your thread joe,,,,what about this turbo??id use the .48 turbine housing i would think.......
http://cgi.ebay.com/ebaymotors/Garrett-T-3-Turbo-Turbocharger-60-trim-T3-Ford-SVO_W0QQcmdZViewItemQQcategoryZ33742QQihZ016QQitemZ260133364336QQrdZ1
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hillfolk,
I moved my post over to your other thread so as not to jack Joe's thread.
Joe,
what is the name of the stuff you used to tape off the block for painting? I've been looking all over for something like that after I read that's what you used. Liquid masking tape? I've found it online, hoping I can find it at a store somewhere.
thanks
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Honestly, what I used to "prep" the block was alot like a petroleum jelly that you'd just buy in the store. It worked great and on the "flange" areas really made the taping off process alot easier...other than that, it was masking tape and alot o' shop towels...
On the turbo above, I think ezekiel's post in your thread on the problems with the holset turbo is right on....especially consider size, flow, temps, etc. etc. I'll post more over in the thread...
Hopefully AWIC installed tomorrow or by the end of the weekend (if it doesn't get done tomorrow because I have the day off...then sat. night/sun will be the next time I get to work on it). Looking good...just tight finding spaces in the MK1 to make things look "clean and neat"
Joe
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Well...the AWIC is finally completely plumbed in, filled with water and working. I have a few refinements that I'll "make as I go" here, but the fact of the matter is that it is up and working, which I'm very happy with.
so... a few pics...
Here is when I first started plumbing in the lines for it... I used some really nice Ag sprayer hose made by Goodyear for the job...nicely sized as well at 3/4" ID throughout the entire system. All total, once filled today it topped off close to 5gal of water.
(http://i18.photobucket.com/albums/b109/joeallison_99/100_3085.jpg)
One thing that took a while was finding decent grommets to fit the body where I made the holes for the water lines to come up through...
ended up in the "HELP" section of the local auto store and pondered...finally, came across a HUGE GM grommet...but it fit PERFECTLY for the hose and the body!!!
(http://i18.photobucket.com/albums/b109/joeallison_99/100_3087.jpg)
Installed one compared to the other line/hole...
(http://i18.photobucket.com/albums/b109/joeallison_99/100_3088.jpg)
Here is what the keg that I used finally looked like after searching through McMaster for the aluminum bungs for it... and my homemade brackets which seem to work really well and keep the setup looking "clean" in the hatch...
(http://i18.photobucket.com/albums/b109/joeallison_99/100_3089.jpg)
So...the final product as it stands at the moment.
I ended up using a Ford lightening/VR6 style aux. water pump as the RV unit I had wasn't up to the task...it was a diaphrapm style and got to be loud once in use for quite a while...
Keg mounted, system filled/bled at this point...I've also made a "mount" for the pump if I want to make it stationary to the spare tire well if need be. I'll also eventually here in the next few weeks be mounting my battery on the opposite side from where the keg is and that'll leave the spare tire well open.
(http://i18.photobucket.com/albums/b109/joeallison_99/100_3099.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/100_3098.jpg)
Here is what you can see of the plumbing of the intercooler from the outside of the car...its not much, and I didn't want to run them down the center of the car of course because of the exhaust...
(http://i18.photobucket.com/albums/b109/joeallison_99/100_3100.jpg)
I'm so glad that with all these additions to the car in the way of drilling, cutting, welding, etc. that I have not done the bodywork yet. Its nice because when i go to do it this winter, I'll have everything "set" the way I want to, be able to weld anything I don't want back up and have a nice clean "ready to install" setup for once I get the paint and bodywork done here. Its a good feeling. Do it once...do it right.
This winter the keg will get a good polishing, as well as the intercooler itself and I'd like to eventually replace the intercooler pipes with some nice aluminum or stainless if I can find something at a decent price...or someone with scrap in the size I need and long enough...
I also am working on figuring out how to make filling the system easier. Originally I wanted to keep the look of the keg "clean" to keep it "keg" looking...so I was going to install a small aluminum res. for filling that would be the highest point in the system either in the back hatch of the car (t'ing off the return line) or installing it up in the front of the car.
Well...as you can see...room in the engine bay is getting hard to find and the piece I got off of EbAY really sucks IMHO and I don't want to use it. I may install a radiator neck/filler neck on the intercooler instelf, or could do it on the keg as well. Still up in the air about it. We'll see.
It is working though and is a nice setup. took it out for a good run after I finished things up and after the run you could easily touch the pipes and tell a distinct difference in temp before and after the intercooler. :) :)
Anyways...so....R520's...please come soon :) and I need to find someone to rebar my injectors!!! Preferably while I'm on the honeymoon so they'll be here when I get back!
Think I might work on upgrading the filter system (fuel) and hiding it (don't like where it is in the engine bay there...) and may try to relocate the pump back closer to the tank if I can find room....its kinda "large" though...we'll see... I'd like to clean up the bay a bit
Joe
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Well, honeymooning in the Outer Banks of N.C. right now! It'll be great to get back home to the mTDI though as its neatly tucked in the garage at the moment. Haven't seen any MK1....spare the cabriolet that was in the VW caravan at my wedding and my friends 16v 2.1 ITB bunny...and another 'vert down here...nothing else...
Nothing interesting diesel wise either with exception to the MASSIVE numbe of Duramax and Powerstroke diesel down here for 4x4'in in the sand North on Highway 12....VERY NICE!!! Makes me want a truck!
Anyways...missing the bunny...hopefully nozzles will be in order when I get home!
Keeping my eye out for bread vans/4bt's while I'm down here too in hopes to snag another pump for the b3 project coming up.
Couldn't ask for better whether though! Maybe next year the trek will be in the mk1 !!!!
Joe
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Heh...Heh...Heh :)
Look what came today!!!
(http://i18.photobucket.com/albums/b109/joeallison_99/100_3148.jpg)
Working on the install now in some 220 bodies I have...
Joe
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Heh...Heh...Heh :)
Look what came today!!!
(http://i18.photobucket.com/albums/b109/joeallison_99/100_3148.jpg)
Working on the install now in some 220 bodies I have...
Joe
I think you'll need bigger turbo again 8)
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LOL...maybe, we'll see. mine is not the 1.6TD unit, I've had several ask about it...its the merc 300D unit. .42cold .48 hot. I've toyed with different ideas for this winter but haven't decided on anything concrete. The selection of the turbo I've found to be one of the most difficult choices on this particular project as I can't settle on one it seems *but haven't tried multiple others*. The lag that you pull from the .48 A/R hot side one here that I'm using isn't dramatic...but does seem to take away that characteristic idle "whistle" through the tailpipe that I had with the standard 1.6 TD garrett unit on the old IDI TD project. Kinda like with the VNT 15 /17 sitting at idle on a stock TDI with mufflerrectomy...kinda miss that sound. This unit does work rather well but considering the t3 design is 20+ years old there are a host of other turbos out there that are more efficient. So...we'll see. The search continues for the "best" combination IMHO. I don't think I'd go much larger on the hot side at .48 A/R but the cold side could use some work...maybe it'll be making a hybrid turbo this winter out of a merc. hot side and something a bit more fun on the cold.
She will do the 30psi and I can't tell you how dramatic the difference is in the intake temps with the AWIC installed. Its quite an amazing system. I've done several runs, pulled over after...felt the boost tubes...WOW. what a difference between the inlet and outlet pipes...and the fact that the intake manifold is just "warm" to the touch...even better :) Its really doing the job nice and I'm not even completely finished as to "how" i want the setup yet!
Joe
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maybe vnt? gt2256v or bigger
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:) It'd have to be a VNT that I'd setup up mechanically...but I've thought that route if possible. Its the one thing that I'd like to bring back that I can't really do with the wastegated unit (with exception to feeding more fuel down low...but it goes against this purpose and doesn't do it the same as a vnt would), is pull back that lag with a VNT.
I feel as if I'm still in that "perfect" turbo search which is why I didn't spend a bundle on the merc turbo in the first place... gt2256....hmm...
I've had thoughts of GT series in my head....a holset....so many options...
Joe
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So...updates...
Well...found a Inari Green parts car that I was able to get the doors and hood off of! So...she finally has a pretty straight hood and the new d side door installed...
THEN:
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3007.jpg)
NOW:
(http://i18.photobucket.com/albums/b109/joeallison_99/100_3151.jpg)
You can't tell from the pics in great detail, but the d side door was pretty "ding'd" up. In several places and it would have taken a door skin from another door to repair it correctly. Same with the D side rear door, but I'll have that on here shortly as well. The PO had the car repainted at one time. "Inari" but, it came out much more of a silver color than the OEM Inari color. Now if I could only find a MINT Inari hatch!
It was interesting with the doors. They came from a 78 and my car is a 79. There were some differences between the doors that needed addressing. Namely, the 78 and earlier doors have a metal weatherstripping channel attached to the front of the door whereas the later doors simply have the weatherstripping "clipped" to the body of the door in the same place. This wouldn't clear with the door mounted. So the channel had to be removed, weatherstripping re-clipped. Also, it had the "early" hinges as well...which wasn't that difficult to swap. Ended up swapping in all of my "good" vent wing window stuff from the "bad" door as the PO had glue the vent windows shut ruining what I thought were some pretty nice seals (despite the fact that they ALL leak).
Well, more decisions body and interior wise for winter...
Body:
Since I'm going to have the engine out to do the 02a swap/setup, etc. I think I'm going to remove the raintray from the car. At the very least, the engine bay will hopefully be detailed this winter...with the final bodywork, paint coming in the spring. Deleting the raintray to me will open up the bay a bit more and make it look "not so crowded". I plan on retaining the heater blower, but building a "box" for around it so it can still pull fresh air. We'll see....
Also...welding in a new D side rocker panel on the car because the current one is quite "crusty" and has gone through in a few area :(
Plan on removing all the sealant in the engine bay area as well, around the strut towers, etc. and then doing some stitch welding with my MIG in those areas too. There will also be a slight repair to the front core support as well as the installation of a core support reinforcement bar as well.
INTERIOR:
Well..continuing to work on getting the seats I've been working on for quite a while ready. The plaid material is awesome and will go great with the Inari paint and I just picked up some really nice black onyx microsuede that I'll be using to recover the door cards which will also have the "plaid" inserts on as well. I'm also considering doing a early MK1 dash, the one really nice one I have...possibly in the fabric (has a few cracks...not major though, so don't know if I want to do that to such a nice early MK1 dash) as well. Contemplating building a false floor in the back of the car to bring the AWIC res/keg up a bit higher in level and also hide the battery which now resides in the trunk.
MECHANICALLY:
Cleaning this up as mentioned above. I'd like to possibly play with a different turbo of similar size to the one I'm running, or rebuild the current one so I can say "EVERYTHING" is new. Also, a new intake setup is in order, playing with Jake's use of the PRM system.
Of course...the 02a swap and I think I'll be using WRD mounts for it as getting them from across the pond will kill me in shipping alone :(
May downgrade my lift pump that I'm currently running which is basically a "Holley Red" fuel pump. Its a nice unit...really nice, but may be overkill for its needs on the mTDI setup. What bothers me worse, is the noise. Its pretty loud and can be heard above the sound of the engine itself! Leaning towards installing it on my 72 westy that could benefit more from it (has dual dell 36's) and run something more similar to a smaller, quieter facet pump hidden back by the tank on the mTDI. Also plan on relocating the fuel filter to the inside of the p. side fender.
This is all barring I have the time to get it done! Student teaching for grad school this winter too....so...we'll see, and there is a possibility of us buying a house in the next month that we've been eyeing....with a VERY nice garage!!! 4 car too!!! So much better than where we are at now! Did I mention, heat, water, electric and cable...LOL.
Anyways...thats an update. Right now, its just enjoying driving the car and staying out of trouble with it. Taking it easy on the 020 and all that good stuff. I have a squeak coming from the accessories somewhere on a cold start, or low rpm "cruise". Its not the crank serpentine pulley (i replaced the stock 1z/AHU one with the updated one) so its either the alternator, h20 pump (but no leaks) or the tensioning mechnism itself.
Its just an annoyance...
Thats good for now!
Joe
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Heh...Heh...
Well, the white stuff is starting to fly...so I guess its time to start looking towards "winter upgrades" again....
A few bits of new stuff....updates...
Day that I shot these nice pics of the mk1 ...here is one...
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3202.jpg)
I somehow managed to snap the dp right in half on the way home that night!!! Sounded like a MACK truck whining all the way home! Fun stuff...SUPER clean break!
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3214.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3213.jpg)
So...today i managed to of course get the dp off so I can repair it just for right now to get the car inspected (DEC) and put it away. I'll be building a new DP this winter...probably a v band unit with another, shorter flex section closer to the discharge. It must have not been a great weld as the motor mounts in the car are fine and in great shape, very little rock. However, the Mk1 front mount...traditionally not the best may have not helped the situation...especially with the torque this beast puts out...
Additionally today....i put on the other "new" good door on the D side...
What once had a front d side and rear d side door that was badly dented in, etc.
Now looks like this!
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3211.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3212.jpg)
I couldn't even find a picture of the "bad side" here on my photobucket...apparently I always shoot it from the p side...hmm...wonder why.
Now if I could only find a nice Inari Green hatch!
However, I do have some body work to do this winter...
These are pics of the D side rocker panel
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3219.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3220.jpg)
Def. going to have to do the D side rocker....contemplating doing the P side as well though pushing on it is fairly "hard" on the p side, but I can hear some cracking....better safe than sorry possibly.
The pans on both sides of the car are great...nothing wrong on the pside.. One small hole, less than a dime on the D side...
Some little work to do around the fender wheels in the rear and one spot on the new rear door I installed today. Looks like that MIG i bought is going to come in handly. Though, I'm hoping rockers don't kill me to do.
Additionally this winter...here is a big part of it...
1 of the 2 of these CTN TDI trans will be going in the mk1 (the one on the left...) the other is for the b3 when I do the mTDI swap for it...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3215.jpg)
Hopefully time and money will allow the b3 swap to occur in the spring. If not, it may be closer or during next summer...but we'll see. The focus is to get the 02a in the Mk1 at this point and some of the bodywork done. Afterall, I do rely on the b3 as the daily at the moment. The b3 mTDI build will be another thread.
Also have some good chrome bits to add to the Mk1 as well. Correct, complete set of 4 chrome handles (just need to find the black trim for them) as well as a set of new chrome flags too. Going to try it...see if i like it. Chrome euro bumpers would be nice....but a bit out of my $$$ flow at the moment. Maybe in the future.
Anyways....thats an update. If anyone wants to help with the rockers in the future...that as experience doing them...that'd be a GREAT help, I can pay with some parts and beer :) if so desired! I don't think it'll be too hard though.
Joe
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Wow, I'm suprised that DP broke off like that despite the flex pipe.
I'm still planning on making those transmission mounts, they were put on the back burner while I got the 1.6 running. If you still need one when you are getting to the transmission swap let me know. I am putting my engine back together and my transmission is almost done so I will be getting mounts together soon.
I bought some sheetmetal from this site when I was doing the body work on my gold car.
http://www.rsjparts.com/catalog/product_info.php?cPath=29_30&products_id=81&osCsid=c81ed6f1125795223eb30680c0f975d0
Doing those rockers should be pretty straightforward if you get decent replacement panels with seam flanges that you could plug weld.
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Justin,
Thanks...I appreciate that and as before, I'm def. in on a mount. I'll need to get them (though, I haven't found the schematic for that rear/lower tranny mount yet).
I know how "busy" gets...today was the first time I had to work on the car in a long time...and it was only a couple hours. However, its SNOWING out now....scary stuff! Guess it won't see much of anymore road time this year.
I'll keep that sheetmetal place in mind...def. a good source...
As for the DP...I was shocked too...its the cleanest break I have ever seen and it was STRAIGHT THROUGH THE WELD!!! I'm going to take it back to the shop where I had it welded up after the swap for adjustments and have them fix it for now. This winter though I'll be building a new one, with v band I hope, and maybe a shorter flex section closer to the turbine discharge. We'll see. Just must have been "enough" to break it.
Also, it was a colder night...car was fairly "cold" on the start...I'm wondering if a variety of issues didn't go into its breaking. Oh well...only going back on temporarily...and has served me well for a number of years. However, for the merc. turbo I'm now running, the dp flange needs to be larger and I'm going to go away from the weld-el construction for the next one... can't wait to hear the whistle at idle again like I did when this was PERFECTLY matched for the old GTD.
As a matter of fact...the flange on this dp I believe it is one that YOU cut!!! Back before anyone was making exhaust, etc. etc. for IDI's or any real performance on TDI's... I've still utilized it to this day... however, I need to open it up for the new DP if I use it again.
Ah...memories...
Joe
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Are you going to use the cable shifter with the new tranny? I've been considering that swap also, but the cable shifter install scares me.
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(http://www.zwalve.eu/d/1368-2/MvT_M-TDI_070924_014.JPG)
(http://www.zwalve.eu/d/1371-2/MvT_M-TDI_070924_015.JPG)
(http://www.zwalve.eu/d/1377-2/MvT_M-TDI_070924_017.JPG)
The 02A gearbox supports I'm making.
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Very nice, and I've seen your mounts before... getting them to this side of the pond is quite a bit more expensive though.
As for the cable shift setup. Yes, I'll be using the full cable box , etc. Instead of doing the hydraulic clutch, I'll be running the cable version for the 02a which I do have all the bits for, etc. as you can also see in Da-Brts pics...
I haven't decided on the box orientation yet...but I'm leaning towards mounting up on the top of the tunnel and running the cables through firewall of the car...it sits the box up higher...which would be nice in an mk1 and also takes up some of the "extra" cable length.
Joe
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If the break is real clean, the weld probably didn't have enough penetration. Those welds do look like they are sitting pretty high which can be an indicator of poor penetration.
Good to hear some of that crude old handywork has survived.
It has been fun getting back into building hotrod Rabbit diesels. I had to drive down to the airport this morning at 5AM buzzing by cars like they were standing still. Can't wait to get the TDI put together, I want to check yours out one of these days.
DA-Brts, that set up is beautiful.
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Getting them over costs about 40 Euro. I've sold them to Canada and California.
The supports have been calculated with a FEM analysis with a safety factor of 2.5 Than took a high grade steel and have them professional welded. The design I made with CatiaV5.
But no more topic polution from my side ;)
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LOL...I think we talked about the price before....can't remember what it worked out to... I believe it was still more than what WRD was wanting, etc. However....they are beautiful pieces! Truly an option...
On the dp...yeah, the weld were sitting particularly high and I remember when I had it welded up the guy that runs the shop was not happy with how his guy had welded it. Its super clean....def. a penetration issue. I'm going to drop it off Weds. for over the holiday and get it back this weekend sometime. Just for temp purposes since I don't have gas for the MIG yet nor enough mandrels, and a flange that I want for the "new" dp.
Mounts are the biggest thing holding me in my way of the 02a conversion at the moment. I have how I'm going to do it for the most part figured out...how I'm going to run the cables, etc.
Joe
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Another SUCCESS for the gasser tach to W terminal conversion FAQ, I did post there as well.
But.... I was able to convert an early Mk1 (round) VDO tachometer to W terminal with success in the last couple of days. I was even able to easily calibrate it on the b3 16v's 90amp alternator as it has an active W terminal.
I'll be able to retain the "early" style dash, cluster, etc. since this works! One of my goals.
No fluctuations and very little adjustment. All adjustment was able to be done at the potentiometer itself...
Good stuff...maybe I'll post a picture of the modified board here in the next few days. My soldering skills are rusty, but getting better I guess...some pretty creative wrapping and and installation a few components in a series.
Hopefully, will get the fixed downpipe back up on the car this week and the exhaust put back together... need to get inspected before I put it away for this year....but a couple last drives and a test of the tacho installed would be nice!!!
Joe
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Cool! Good to know that works! Looks like that's what I'll be doing on the Rocco, as it also has a round VDO tach. Not sure on the alternator though, I never bothered to check if it has the "W" terminal. Do newer TDI-alternators have a W terminal as well? I was gonna go with a newer style 90amp TDI alt with serp setup.
Brendan
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Actually...
Alot of the alternators on 83+ cars have the W terminal. Mainly, I've only ever seen these as 65 amp or 90amp units. The b3's alternator is a 90amp gasser version...it had it...my 'rado had it and also my brothers 91 gasser as well. So..its not unique only to diesel cars. :) So, chances are, you'll have luck.
Also...my mTDI mk1 runs a 90amp 2.0 gasser alternator with the serp belt setup right now...I'm hunting for a TDI 120amp unit, or a VR6 unit. Same deal...different pulley (7 rib vs. 5? can't remember).
Anyways...the serp belt style alternators also have the W terminal as well. All the ones I have seen anyways. It shares a 2 prong plug, standard VW connection with the alternators D terminal, or the exciter :)
So the answer is yes....it should have one! I'll be able to let you know very soon as I'll be hooking this up in the mTDI very quickly.
Just to note...the early speedos/tachs do come in variations...the first "early" round Mk1 gasser tach I had..from 78 or so... was a MOTOMETER unit...
This one I modified was a VDO unit, as mentioned...must have been from the "transition" mk1's, one of the first Westmoreland cars is my guess, as it shares the same configuration as the Westmoreland GTI's...
Make sense? No...these weren't made in Westmoreland... they were made in Germany of course...but the cars they were installed in were the "westmoreland" or later MK1's (late 79-early mid 80...share the "round" headlight fenders, but had the "westy" grill that didn't wrap around with turn signals and it has square headlights...short tails still on the rear).
Anyways...if anyone cared :)
Joe
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Well, I finally got a chance to start up the mTDI Rabbit again here today. After fixing the dowpipe, etc. etc. and getting the exhaust hooked back together all is well. Just hadn't had the time
Also, I was able to full intergrate the tach into the early dash, I even used the factory german cluster plug and was able to change out the connections needed for a "factory" hookup and look so that I didn't have to tape off terminals, add connections, etc. The early MK1 cluster plugs are actually really nice to work with, They come apart EASY which makes swapping connections really easy as well. I ended up switching to the motormeter circuit sheet that I had as the VDO one was pretty bad. After comparing them though I didn't see any major differences, etc. and everything is good to go!
Idles a bit high. at about 1.5k and I don' t think the engine is actually idling that high so I think that accounts for the difference in between the pulleys on the test/calibration car (my 16v b3 gasser ) and the mTDI engine running serp belts and the 2.0 90amp alternator.
Easy enough to fix though...
Here are a few pics...as promised...
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3230.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3232.jpg)
Had that second one revved quite a bit higher...but my digi cam recycle time SUCKS.... either way. No flutter, etc. I'm going to need to find another "VDO" parts tach for a good needle (as this ones paint is damaged and/or do something with the needles. The biggest drawback I think with the older gauges is the illumination itself...
Hmm...maybe an LED project in the future!!!
Either way...WORKING CONVERTED GASSER TACH!!! WAHOO!!!
Next...decent weather to get an inspection and then...winter hibernation...for hopefully the 02a upgrade. Still have the mount issue to tackle and no $$$ to do so...
Grr... too many projects.
Joe
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Looks good Joe. I put VDO LED bulb replacements in my Rabbit, it was easy and made a vast improvement. I don't know whats involved in those old gauges though.
What did you end up working out with that welding shop? Did they build you a fresh bew DP?
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might be a good deal to try...LED's that is. These are the twist in style bulbs...that just "pull" out of the twist in holder. I might see if I can do LED's...
As for the DP. No...its not a new one :( I had them just repair it for now. The plan is to build a new one this winter. This bugger has been good to me though....weld'els and all! and has never busted an stud or anything. However, the diameter is now not good for the size turbo I'm running.
I'm trying to figure with the "new" dp whether I can elminate that snake curve that you have to do in the Mk1 to avoid the shift linkage ( and just do a fairly straight shot with maybe a shorter flex coupler in that section)...especially since I'm going to install the 02a CTN trans this winter. I just need to figure out the mounts for that too.
Joe
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The LED bulbs I used popped right into the VW/VDO bulb holders. The only modification I had to make was to pull the green difuser out of the Westy cluster and replace it with a clear frosted one (since I used blue LEDs).
What turbo are you using? I used the VNT-15 turbo and manifold off my ALH and was able to run the DP without that little curve. My DP is 2.25", I used the flange and first 90 degree bend from the Golf TDI DP and welded an angled tube onto it.
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The LED bulbs I used popped right into the VW/VDO bulb holders. The only modification I had to make was to pull the green difuser out of the Westy cluster and replace it with a clear frosted one (since I used blue LEDs).
What turbo are you using? I used the VNT-15 turbo and manifold off my ALH and was able to run the DP without that little curve. My DP is 2.25", I used the flange and first 90 degree bend from the Golf TDI DP and welded an angled tube onto it.
I'll look into the LED's, where did you source them from just out of curiousity. The nice thing with the early clusters, they are like my buses cluster and beetles :) They have NO diffuser in them, etc. So, I could do colored LED's, change the color or just simply make it brighter :) Rather easily.
As for the turbo. I'm currently using a Merc 300D turbo....42 cold, .48 hot... I like it, especially with my motor build...but I'd really like to head to the route of a Holset hybrid of some kind :) I can tell you what I'd like for what I think would be the "perfect" wastegated turbo for this motor (single...not a twin turbo), but I've yet to find/source the parts for it (could be done via a holset, or a Garrett model). My T3 sits on a backset/center flanged 8v manifold.
I def. haven't jumped on the VNT bandwagon but do have quite a bit of experience with them. The way my manifold sits mounts the turbo higher up on the block, but farther back on the motor itself (when compared to a standard IDI t3/KKK setup or a VNT). The VNT actually sits down on the block and would def. indeed remove the need for the "snake curve" i mention. It also could just be the way I built the pipe. :) I'll know when I tear into it. Before I think about the 02a this winter though in the mk1, I need to secure funds to get the mounts...otherwise, it might have to wait. I just realized what I've gotten myself into trying to do/build the passats mTDI motor this winter and still convert the mk1 to 02a (not to mention my full time commitment to student teaching coming up in Jan. 08 and no income on my part). So...we shall see :)
Joe
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I bought the LEDs from New South Performance and they are VDO parts so anybody who carries VDO should be able to get them.
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will check it out....
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Im building a 1.6 na to td and im going to be using the g60 gasser manifold.Are we going to have any clearence issues with the turbo?You said your running a back set,What other options am i going to have with the gasser manifold as far as turbo position?I realize it should be easier to run from the ic to the intake.I dont have my car yet (just engine)so im having trouble visualizing positions.
ben
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Im building a 1.6 na to td and im going to be using the g60 gasser manifold.Are we going to have any clearence issues with the turbo?You said your running a back set,What other options am i going to have with the gasser manifold as far as turbo position?I realize it should be easier to run from the ic to the intake.I dont have my car yet (just engine)so im having trouble visualizing positions.
ben
Best posted in the IDI forums since it sounds like that is what you are dealing with, but i'll give a little info here.
The clearance issues with the turbo/intake manifold will depend on what exhaust manifold and turbo configuration you are using. If you are using a IDI TD exhaust manifold (from either a 1.6 or a 1.9aaz), if you try and use it in the "stock" position, the turbo sits up on the manifold more towards the "top" of the manifold and you won't be able to clear a gasser intake. A solution is to "flip" the manifold over and use it that way... then you have the exhaust discharge problem to deal with (on p side instead of D side...) .
A VNT configuration...as many seem to be using, would be a different story which mounts the turbo much lower and below the exhaust manifold opening up space for the intake manifold.
Another is to use a "backset" manifold like alot of your standard 8v manifolds are. If you look back in the post, you'll see what it looks like. I also am running a spacer in mine as well to clear the compressor housing of the turbo. I had a substantial amount of grinding and clearancing to do to the manifold too (besides the port job).
Joe
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Wow, this is really incredable, motivates me to go out in canadian -20 degree winter and work the turbo into my 1.5L set up
cheers man, Great work your doing there!
props!
-J
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Correct, complete set of 4 chrome handles (just need to find the black trim for them)
Joe
Hey Joe! Have you found the trims yet?
I made the later model stailess trims to fit my chrome handles. All shiny handles now :D
Pic (http://www.kotinet.com/matti.farm/Scirocco/IMG_2657.jpg)
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WOW it has been a crazy long time since I updated this thread. Its been a busy summer though...
Some things that have happened...
Well....we moved is the biggest thing. Still in the Elmira, NY area...but bought our own house, with a newly built garage as well. PO only had one of those plug in flourescent lights in the garage and I had to improve on that....
Here is the Rabbit and Westy's new home....
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/DSCF1134.jpg)
My lighting improvements. I LOVE CRAIGSLIST!!! I got these fixtures (40-60.00 fixtures from Lowes/Home Depot) for 1.00 a piece! I managed to get all of them... 5 4-bulb fixtures and 9 2-bulb units for a whopping 14.00!!!
Anyways....6 of them ended up in the garage. The 4 bulb fixtures (x4) in the rear and middle of the garage and then (x2) 2-bulb fixtures above the garage door when the door is shut....PLENTY of light :) Finally!!! You can actually see the b3's mTDI build started there on the engine stand....working on that as we speak
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/DSCF1133.jpg)
So....I was thinking about having finally broken the engine in that I was comfortable to open it up just a bit more. The 02a is still sitting...waiting and ready to go in the mk1, but I just didn't get there this year. Here is a shot of that.
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/DSCF0748.jpg)
So...today. Governor mod...
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/DSCF1137.jpg)
All I have to say is WOW!!!! I shimmed the int. spring 1/8 and the main spring by about 1/4". Once I got it all back together of course it took some fine tuning of the pump and such but I am super impressed with the result. I can probably shim the main more if I wanted too, but I am good with this until that 02a is in this winter (along with all paint/bodywork...wait til you see what I have planned there). I just can't wait to really be able to play with the car once the new tranny is in.
Just to confirm...for others (and reaching back to the Governor thread in the FAQ), as Jimfoo and others noted. It was required of me to turn back the full power/residual fuel screw once I did the gov. mod as well as back off my idle. I am actually backed as far off as I can be on the idle without having to change the throttle positon on the shaft itself (currently at about 10-11 o'clock (the hash))
It is NUTS on the road :)
Joe
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Paint, bodywork, 02a CTN trans upgrade this winter, interior as well as other bits. Especially now, at the new place, new job...garage....etc.
Here are some things I'm working on at the moment. Just enjoying driving honestly right now befoe it has to go away for winter.
Bought a original ZVW rack for the Mk1...kinda like the look. Its in pretty good shape. It was tweaked a bit when i set it on the car and the drivers side "posts" look like they have been bent before...or clamped for some reason. Anyways, the clamps that were with it after doing some searching were not the original clamps. One "worked", and the other wouldn't even pull to my roofline if I tried. So, I tried my hand crafting something using some aluminum bar stock I had around. I'll be refining them this winter I think, but road tests show they are working REALLY well and they are "super" clean looking and pretty damn close to what the OE clamp looked like...
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/DSCF1194.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/DSCF1192.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/DSCF1191.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/DSCF1193.jpg)
Another thing I have been working on is a new CCV vent system for my mTDI setup. I originally was using a "OLD NAVY" CCV from an ALH engine. This setup had a single port on it which required installing a block off plate on the 1z/AHU motors and elminate the block vent. I didn't like the setup and went back to the factory 'elephant hose'. I have two of these units here and one is brand new, and continues to leak at the CCV puck. I think it has to do with the clamp used on it and since it does clamp "completely round" so it leaks a bit. I never was happy with it and have started working on a variation of the KC TDI mod for CCV found on TDI CLUB.com
I'm using reinforced high pressure hose
An Agricultural filter
Stainless steel scrubbing pad
a crankcase vent plate (from 1.6 NA engine)
various connections.
In doing so, I'll have an efficient CCV system that is not venting to the atmosphere but is keeping anything in the intake tract nice and clear!
Some pics...
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/DSCF1183.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/DSCF1187.jpg)
Here it is sitting on the other mTDI motor I'm building for the b3...fits perfectly on the block (1z/AHU....ALH = no crankcase vent on block)
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/DSCF1188.jpg)
More update to come. Need to update the b3 mTDI build too....bottom end is almost completely done.
Joe
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Nice to see some update!
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Correct, complete set of 4 chrome handles (just need to find the black trim for them)
Joe
Hey Joe! Have you found the trims yet?
I made the later model stailess trims to fit my chrome handles. All shiny handles now :D
Pic (http://www.kotinet.com/matti.farm/Scirocco/IMG_2657.jpg)
so how'd ya do it? make them fit so well i got the same problem can't find decent handle trim!
Duane
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Trims are just glued to handle. Had to cut the clips for plastic handle away.
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That is a good looking car even in it's current state..
I have a mk1 fetish though. :oops:
My first car was a 81 white 4dr Rabbit. Man I had fun in that car.
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Correct, complete set of 4 chrome handles (just need to find the black trim for them)
Joe
Hey Joe! Have you found the trims yet?
I made the later model stailess trims to fit my chrome handles. All shiny handles now :D
Pic (http://www.kotinet.com/matti.farm/Scirocco/IMG_2657.jpg)
so how'd ya do it? make them fit so well i got the same problem can't find decent handle trim!
Duane
I wanted the original look. The actual trims to fit the door handles are still available through VW and FAR less than what people are asking on flea bay.
As for the "finish" product. Well...far from finished I feel but the spring will bring a much more "finished" look to things.
Joe
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best build thread ive seen in a long time, once i started i had to see it all, btw very impressed, good engine, although it does lead me to believe that you have no life :lol:
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it seems i don't... Work....car...lol...
No. I do, but I don't do alot of other things. I'm a first year school teacher having started this year after getting my masters degree...so I have been busy. The cars....*westy, the mk1 mTDI and the b3 mTDI build* are my hobby and we just bought a house this summer...so, it seems like I don't do much of anything else. I enjoy it though :)
Joe