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Engine Specific Info and Questions => IDI Engine => Topic started by: wolf_walker on April 16, 2013, 11:41:47 am
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http://i204.photobucket.com/albums/bb18/fenwick458/CIMG0032.jpg (http://i204.photobucket.com/albums/bb18/fenwick458/CIMG0032.jpg)
pic found with google search
Is a D port NA 1.9L IDI intake, I think from a 1Y of some sort though I'm fuzzy on what is what exactly.
I'm sure they aren't common but I've been toying with the idea of trying to run one down for my
NA 1.9L, since the head ports match. It's got to be preferable than the oval parts on the 1.6L intake.
Thoughts/experience? I know nobody bothers with a NA 1.9 by choice but I figured I'd ask.
Also any clue what country these might be most common in?
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i have one like that, it has an extra port on it so i think its egr from a later sdi or something. i can't remember how i even got it. definitely came on engines in europe tho, i think 1y was definitely one of them.
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I saw a pic of an SDI intake that was huuuge with plastic long runners that laid over the front of the motor, but there may well be others.
I don't even know the names of the damn cars they sold in Europe other than the stuff that came here as well, it's hard tracking stuff down.
Thanks for the info.
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I had one of those on my 1.9na. I installed it when I did a pile of other work to the car though so I don't really know what effect it had. I've since given the car to my brother.
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Groovy.. Now if I can just procure one.
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I've since given the car to my brother.
Does he not drive the (che)vette any more? :(
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I saw a pic of an SDI intake that was huuuge with plastic long runners that laid over the front of the motor, but there may well be others.
I don't even know the names of the damn cars they sold in Europe other than the stuff that came here as well, it's hard tracking stuff down.
Thanks for the info.
Yep I had one like that too but I sold it cause it won't work on an idi it will hit the pump. But there's a bunch of different ones, all very interesting looking
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I've since given the car to my brother.
Does he not drive the (che)vette any more? :(
That's my other brother.
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I saw a pic of an SDI intake that was huuuge with plastic long runners that laid over the front of the motor, but there may well be others.
I don't even know the names of the damn cars they sold in Europe other than the stuff that came here as well, it's hard tracking stuff down.
Thanks for the info.
Yep I had one like that too but I sold it cause it won't work on an idi it will hit the pump. But there's a bunch of different ones, all very interesting looking
Yes, there's even ones that are like snails, with the plenum in the middle of the runners which curl around it from the head mating surface, giving the effect of the other straight long-runner SDI mani without the bulk. If you want long runners for a little inertial cylinder filling it might be worth considering that manifold. Google 'SDI snail manifold'; here's one:
(http://www.darkside-developments.co.uk/images/TDIClub/SDI%20Complete.jpg)
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Hmm, interesting. Wonder if there is room for it in a rabbit.
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i have one i my passat,but i modified it so the opening to be on the other side,for plumbing of the intercooler
that is the 1y intake.
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Hmm, interesting. Wonder if there is room for it in a rabbit.
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If the old box NA mani can fit, that that definitely can. :)
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Seems so, not sure how to plumb either but I think the pass side inlet might be easier.
The snail one is actually more common it seems on ebay and such.
I e-mailed that outfit here in CA that sells all the 1.9's and such with a photo to see if they have
anything available.
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Well so far nada on the 1Y intake, maybe on the snail but the inlet appears to be on the wrong side on most if not all of them.
Saw one off a T4 Transporter in a far away land but I can't tell just how different it is, though it looks close.
It was suggested to use a 1.8L gasser intake and match the ports up, I'm assuming there is enough meat there to do so.
I think I might be inclined to just use the intake I have if I were to go that route though. There is good data out there about
intake port flow on the gasser intakes, but nothing on the diesels to compare it to. Plus I have no idea exactly what a NA diesel
might want in terms of intake flow compared to a gasser. There are rules for port size/volume VS cylinder size and etc, etc, etc
but this is just an ole NA diesel daily after all.
As much as anything I wanted that single CCV port on the 1Y intake, I notice it's pretty huge compared to the two small
one's all the 1.6's had, and it does not seem to be metered like they were. I see a trend toward larger diameter hoses on the CCV
system with VW over the years and I assume it's with good reason. Hmm...
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As far as the Snail manis that have the inlets incorrectly oriented, are they pointing toward the driver's side? If not, have you considered fabricating a direction pipe for them? Either that or getting a digifart airbox and running it?
What car is this engine in, anyway?
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82 Caddy. Really not wanting a driver's side intake, lot of crap there already.
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Well, I found an intake for what I was willing to pay I think, it's an EGR model but looks easy enough to blank off.
Don't think I'm going to find anything else in the timeframe I have to work with so it's this or nothing.
Now I have to cobble an intake hose and filter.
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Any pics?
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Shortly yeah, on phone. Cleaning up my old TD air box to use with this intake.
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https://www.box.com/s/zqbkfwcpw05l75grcg3o (https://www.box.com/s/zqbkfwcpw05l75grcg3o)
https://www.box.com/s/a3gj63uivqmeqb66fd31 (https://www.box.com/s/a3gj63uivqmeqb66fd31)
https://www.box.com/s/co6gl1n3u8w1qq72cs6n (https://www.box.com/s/co6gl1n3u8w1qq72cs6n)
Looks easy enough to block off the EGR. Isn't as aesthetically pleasing as the non-EGR model but such is life I guess.
I cleaned up my old Jetta TD airbox that I used when the AAZ was turbo'd last, got to find a hose to connect intake to
airbox, don't know what size the intake inlet fitting is.
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Wolf -
I think the stock 1.6TD airbox is close to 2.5" diam. at the outlet (...and just about the same as the black fitting on the manifold). I've trial fit a silicone connector to leftover 2.5" aluminum intercooler pipe that will likely be used to connect to a 2.5" K&N cone filter as I don't have a stock 1.6TD airbox available.
Where/how are you locating the fuel filter with the new manifold? I'm putting the non-EGR version of that manifold into a 1982 caddy and will be moving the filter to just fwd of the passenger strut housing & looking for some photos/ideas of best way to do
this.
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Wolf -
I think the stock 1.6TD airbox is close to 2.5" diam. at the outlet (...and just about the same as the black fitting on the manifold). I've trial fit a silicone connector to leftover 2.5" aluminum intercooler pipe that will likely be used to connect to a 2.5" K&N cone filter as I don't have a stock 1.6TD airbox available.
Where/how are you locating the fuel filter with the new manifold? I'm putting the non-EGR version of that manifold into a 1982 caddy and will be moving the filter to just fwd of the passenger strut housing & looking for some photos/ideas of best way to do
this.
Well, the TD airbox was in there back when the motor was still turbo'd and I think I had the filter on the back side, sorta, of the pass side strut tower, but I'm open to it being elsewhere.
Figured I'd trial fit the box this weekend and see what it looks like. Figures I just replaced all my fuel lines with nice cloth covered German stuff, oh well.
I'd use a cone filter tucked somewhere if there was one I could trust that didn't cost a fortune. Can't go but so wrong with a factory filter I figure, and the box is laying around, so..
What motor are you using? I figured I was the only one using one of these in NA trim by choice. :)
I envy you the non-EGR. I haven't ruled out cutting it off and having the hole welded up if I can find someone willing.
But I'll probably wuss out and just blank it off at the valve flange.
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Engine is a 1.9 n/a (engine code 1Y) that just blew a headgasket @ 7,000 miles due to a cracked thermostat housing that split apart. I believe it to be a new crate engine from VW - not a rebuild. Funny thing is that the head doesn't have any markings on it (part number, mfg, date stamp). Pistons are marked with the KS stamp and the seller claimed that it was a VW industrial engine: the Bosch pump looks funny to me as it has no manual fuel advance lever next to the engine block and some sort of solenoid on the front side with a small metal tube that goes to the top of the pump by the fuel inlet.
<<anyone>> Does the plastic camshaft splash shield for 1.5/1.6 engines fit on a 1.9 with the different valve cover mounting? thx
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Your pump sounds like mine, Google KSB, dodge trucks have them. I believe the baffle will fit, I have one to install here shortly.
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Well my airbox is 2 3/4" OD, will see next week what the intake is.
I suspect I'm going to end up with a silicone 90 on the intake and flexible exhaust tubing for the short run to the intake.
Rock3tman, are you running 1.6 timing and accessory stuff or a full 1Y setup?
We have essentially the same motor, mine is a de-turbo'd AAZ.
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1.6 n/a timing belt cover spaced with washers & a short flat bar piece on the mount that's by the injection pump.
1.6 n/a alternator mount & v-belt setup (crank pulley, waterpump pulley, & alternator pulley); no a/c. Did 1Y come with a serp setup initially?
I'm assuming that crank sprocket, injection pump & cam sprockets, and tensioner is stock 1Y/AAZ stuff, also thanks for the tip on oil shield fitment.
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Not sure on the serp belt to be honest, mine is all 1.6 stuff, mix or A1 and A2.
If you stall a few weeks I can tell you for sure on the oil shield, but I'm almost sure it'll just take
some fiddling with at worst, the basic shape of that stuff is still the same up there. I saw one
for an AAZ/1Y in the parts catalog awhile ago but didn't note the part number.
Are you running the 1Y CCV setup or the 1.6 stuff?
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I put the head back on Friday w/ ARP studs, torqued to 45, then 85, then 125 per their sequencing & data sheet...man, it really felt like a lot of force!!! I'll pick up a 1.6 oil shield this week and see what I've got for fitment issues- hope to be running by next Thurs or so. Just need to hook everything back up, relocate fuel filter and replace fluids.
The CCV is a 1.6 n/a hockey puck that will now go into the fitting on the 1Y (non-EGR) intake instead of the old 1.6 n/a manifold with mismatched port & runners...
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Cool deal, there's a plastic Jose going down to the front of the block for the stock 1Y CCV stuff as well.
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Intake acquired, now how do I get the EGR leavings out of it.. lol
The TDI guys seem to burn it out, wonder if letting it sit in a bucket of biodiesel for a few days will soften it up enough
to spray away?
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Intake acquired, now how do I get the EGR leavings out of it.. lol
The TDI guys seem to burn it out, wonder if letting it sit in a bucket of biodiesel for a few days will soften it up enough
to spray away?
Fire is the agreed upon easiest and fastest way to get the coke out of the intake..
or you could try bio-d, and some heavy duty scrubbing..
i used the hot tank at my school to get lighter deposits out of TDI intakes..
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Course I can't find bio-d when I actually need some. One joint in town seems to want a membership or some such.
It's not crazy bad like the TDI's get, just sludgy in the EGR passage and at the curve down to the runners on the backside, right
where you'd expect stuff to gather. I'll much with it a bit and see what I can do.
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Maybe carb cleaner? I haven't used it in years so they may have backed off on how strong it is but as I recall, it was pretty knarley at removing stuff from aluminum.
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acetone and atf i hear disolves deposits pretty well. probably could mix up a big batch pretty cheap and let it soak for a day or two.
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They don't seem to sell chlorinated brake cleaner here, which was my first thought. The house brand autozone carb cleaner made a pretty fair dent in it though. The process continues.
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The longer runners on the NA intake are a bit of a challenge, as is the EGR passage itself.
A braided steel cable with one end frayed out and the other end chocked in a drill seems to
work well for cleaning it out too. Still some crud on the post-hump side of the EGR
but it's getting better.
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The longer runners on the NA intake are a bit of a challenge, as is the EGR passage itself.
A braided steel cable with one end frayed out and the other end chocked in a drill seems to
work well for cleaning it out too. Still some crud on the post-hump side of the EGR
but it's getting better.
a hardcore baby bottle brush or wine bottle brush in a drill. you can get the ones for 5gallon carboys at brew shops theyre about a meter long and flexy.
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Made one with braided steel cable, frayed one end, plastic coated cable, worked well.
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Well, I found an intake for what I was willing to pay I think, it's an EGR model but looks easy enough to blank off.
Don't think I'm going to find anything else in the timeframe I have to work with so it's this or nothing.
Now I have to cobble an intake hose and filter.
So what kind of intake did you end up with?
Any pictures?
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http://imageshack.us/a/img268/6186/20130501193722240009323.jpg
Thought about cutting the egr tube off and welding up the hole, but screw it, block off plate it is. Few weeks from install.
And I bought a pop tester and six sets of core injectors. :-)
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For future reference, runners are 11 inches more or less from flange to plenum entry.
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