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Messages - Alleslowbuged

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1
IDI Engine / Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« on: May 24, 2018, 09:57:04 am »
Hi,

good news, Photobucket is back in business and therefore my pictures are back.

Best Regrads
Alleslowbuged

2
IDI Engine / Re: Head gasket fix in a bottle?
« on: February 20, 2017, 04:09:15 pm »
I have used the Bars Leaks Head gasket repair - the silver bottle that costs 25-30 usd. No need to drain, refill and all that ish. Just put it in.

Un-flucking believable... did the trick on a trashed Intrepid that would blast coolant out the expansion tank after running for ten minutes. I think it needed another dose after a year.

YMMV, of course.

Hi,

the stuff is really impressive, i have used it serveral times and it worked really good. Two times - issue solved, otherwise keep the car running for more than one additionally year, to be prepared for the real repair. If i would shedule to drive through the sahara, i would have some bottles with me.

Best regards
 

3
IDI Engine / Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« on: February 19, 2017, 05:55:41 pm »
Hi,

i forget the intake manifold:



Best Regards
Alleslowbuged

4
IDI Engine / Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« on: February 19, 2017, 05:44:06 pm »
​Hi,

the head is ready, i get pictures from the porting guy today:












I am counting days (weeks) now...

Best Regards
Alleslowbuged

5
IDI Engine / Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« on: January 20, 2017, 05:04:15 pm »
Hi,

so not much news here. The head and intake are in finnland, the pump and the 0.280 gibonta nozzle are here and wait for installation. I have wait a few day for feedback from the turbo supplier, but get his feedback now. I will send him my manifold an my last used Schwitzer S2A turbo as template, so that he can adjust postion and degree of rotation of the turbo.

Best Regards
Alleslowbuged 

6
IDI Engine / Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« on: January 05, 2017, 04:59:54 pm »
Hi,

here are some pics of the intake:







looks good


not so good


comparison with Pd150 intake










I would love to increase the volume of the plenum and make it a dual plenum, but i can not weld alu und all my attemps to built a "custom" intake did not went well - pherhaps somtime in the future
 
Best Regards
Alleslowbuged

7
IDI Engine / Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« on: January 05, 2017, 04:10:45 pm »
Hi,

@RabbitJockey

I agree, that it would make more sence to keep the black golf together and just make it better with parts from "my" (red) Golf. But it would have make even more sence to buy an MKIV with an stock AHF / ASV engine and just bolt some parts on it. If you have make a Golf MKII ready to cope with 200hp, the weight advantage shrinks to just a fraction.

To be honest, i mainly keep my golf, because i have some kind of relationship to all my cars and after having a lot of ups and downs (more ups) over a couple of years, it seems just not fair to jump in next best car available and forget the old one. It is also not good for the KARMA -- a friend has swaped her motorcycle to a newer one of the same model, just because it was newer and than has only has problems the hole year. The old one was bougth as new by her and never missed a beat over serveral years.

The black golf is worse than the pictures suggest, but not bad at all. At least it would also need some work to finalize and there are also some pros for my golf, it has PU bushings all around, widen weel arches to fit et13 rims and look nearly oem, brand new rear disks, new front subframe, front splitter, nicer interior and at least it is red (i like red more than black on cars).

Best Regards
Alleslowbuged

P.S. I try to convince my friend, who will help me with the engine swap, that he wants the black golf and i suggest that he will organize a new AAZ block and we will put a new AAZ (~160-170hp) in the black one.

8
IDI Engine / Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« on: January 04, 2017, 03:16:48 pm »
Hi,

i came to a conclusion regarding the nozzle size. As written i was unsure if 0.260 or 0.280 would be best and came up with the following thoughts:

The Afn has 110hp, a 10mm pumphead and 0.205 nozzles as stock and i would say that there is at least 20% margin left in regard of fuel / power without sacrificing injection time duration to much. So i can say, a 10mm pump head and 0,205 nozzles are good for min. 132 hp with suitable injection time duration and good atomisation.

When i go from 10mm head to 12mm head this means an increase of 44% in regard of flow per stroke (assuming that the volumentric effeciency is the same , even if it is not the same at high rpms). So by increasing nozzle size also by 44% should bring similiar injection time duration, injection pressures and atomisation @ 44% higher fuel rate and therefor 44% more engine power. This would mean 190hp and 0.246 nozzles.

So to go over 190hp means either bigger pump head than 12mm, or increase injetion time durartion to get more flow, or sacrificing atomisation by using bigger nozzles. As i want to rev to a certain level, bigger pump head is no option.

So its injection time vs. atomisation to find the best compromise. The nearest available nozzle options are 0.260 and 0.280, which means 14% vs. 30% higher flow rates above the calculated 0.246. In engine power this would mean 216 hp vs. 246 hp with a similar injection time duration as a stock AFN with a 20% remap, but worsen atomisation.

I think based on this thoughs both nozzles sizes would be still an option, but it is clear that the 0.260 nozzle will not have much margin left @ 230hp in terms of suitable injection duration times. Adding the fact that the 12mm head will loose some of its volumetric efficiency at higher rpms, the margin will be even smaller, even if i have no doubt that 230hp will be possible with 12mm head and 0.260 nozzles.

My shedule is to use 0.280 gibonta nozzles, mainly because i am concerned about the cambelt and the high pressure plunger. If i would use a 12mm head with 0.246 nozzle @ 190hp, this would mean approximate 44% more torque for the pump plunger and the cam belt to handle. For the 0.260 and 0.280 nozzles @ 230 hp i am not so sure about the percentage increase in torque, because both will end up with lower injection pressures, but it is for sure that the 0.280 nozzles will stress the pump and the cam belt less than the 0.260 nozzles.

Just to make clear, i know that all this is only a simple a linear approach and the reality is bit more complex, but as we speaking about a fluid as medium i think the approach as above, should be suitable for getting some rough numbers to orientate. To realy see the mentioned power figures there should be enough air to burn all the fuel injected as well, but this is another topic.

Best Regards
Alleslowbuged

9
IDI Engine / Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« on: December 31, 2016, 02:14:59 pm »
Hi,

i have ordered an AFN pump with 12 mm head and DE110 camplate (3,1 mm stroke) today, so that is fixed also.

Best Regards and a nice to 2017 to everybody
Alleslowbuged

10
IDI Engine / Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« on: December 30, 2016, 06:10:08 pm »
Hi,

here are some pics as update and keep the thread a bit more alive, as only a lot of text.

This is "my" Golf last week:



and this is from wednesday:

head pulled:


search for the failure (tip: keep an eye on all pistons)


some extra ventilation for the oil pan


The head looks and feels fully ok


if someone want a ported AAZ head with regrinded camshaft, valves seats mashined to run with stock bottom end and ready for 190hp, here it is for sale:
 


and here are some pics of the donor car, it is a little bit a shame to strip it back:

Golf MKII
- plus axles with 5x100 and 288er brakes
- e-gas and hydraulic clutch actuator
- e-windows
- central locking
- full converted wiring loom to fit AFN engine with fully working seat ibiza tacho with MFA
- 02a gearbox
- good interior
- power steering
- etc..

first day:






wednesday:




I am realy happy that i could fix the "no power" issue today, because now i know i can swap 1:1 all the parts and the engine will run in my golf also.

Best Regards
Alleslowbuged

11
IDI Engine / Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« on: December 23, 2016, 06:50:15 pm »
Hi,

i have increased my power goal to 230hp and have ordered a ported head with 37/33 oversized valved and a performace cam with 9.5mm lift today. I would have liked to use a 10mm cam, but than i must have pulled the pistons and machine the valve grooves.

The turbo has also changed to a GTB2060VKLR with ball bearings, vacuum control and a T3 flange, which will be installed on my kinetic manifold, so general arrangement will be as with the AAZ.

Due to the increased power goal i will also using bigger nozzles, but i struggle to decide if either 0.28 oder 0.32 would be better. The pump will be with electronic control and i will use the 12mm plunger from my mechanical pump. I was told to use the camplate from an ALH pump (DE134), did anybody here knows what stroke that has and if there is an different to the AFN camplate with 4,1 mm stroke?

So the plan is ready and i need parts and time to install them. I have also started to strip the AAZ, but the cylinderhead is still in place so i do not know how the cylinder and pistions looks, but i will make pictures if the head is down.

12
IDI Engine / Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« on: December 14, 2016, 06:00:28 pm »
Hi,

i am get some progress in my overall plan, actual it looks like 200hp with matching hardware to make it reliable.

fixed (nearly) shedule:

- ported head, pherhaps with bigger valves,
- regrinded camshaft
- ARP head bolts
- GTB2056VK Turbo
- 0.260er Nozzles
- d=11 (pherhaps d=12) plunger for the injection pump
- custom intake - Volvo 5-cylinder

open shedule:

- Exhaust manifold (tubular type - facing down, or the same as before - facing up)
- intercoller (stock GTD as before, or front mounted)
- IP elektronic / mechanic oder mechanic with electronic timing control

I know that using the full electronic package would be the best solution, but the idea of an 200hp TDI in an MKII Golf, with an mechanical pump, upfacing turbo and stock GTD intercooler, which looks like the stock 1.6TD at the first glance, is very appealing to me.

I do not have any experience with M-TDI's, so i do not have any experience if it is possible to handle that properly. I would like to use a mechanical pump with electronic timing control, as in the latest AAZ's, because i think that is the weakest point of the mechnical package. I have had the thougth of swapping the hole package and than swap the pump to an mechanical with elec. timing control and only conect the PWM valve to the harness. But i do not know if the ecu will work, when the pump head is not conected and i would need e-throttle and cable at the same time. So only woolgathering.

Best Regards
Alleslowbuged


13
IDI Engine / Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« on: December 09, 2016, 05:39:55 pm »
Hi,

i do not know the block code, but it should be the same as 1Z / AHU and the earlier type 1.9 TDI's. I think the AFN was the first with VTG turbo and it have a more step (4,1mm) camplete  in the injecton pump. The stock power is 110hp.

I will go for VTG turbo, but bigger than stock, or to say biggest i find. My daily driver is a BMW E34 525TDS since a couple of years and i am running a GT2556V (E39 530D) with boost can an electronic boost controler. The BMW has an autobox and do not see to high rpm's quite often, the boost control with the electronic boost controller works quite well, i only have slightly overboost by going full load after no load at higher rpm's. Which turbo i use is still open, i could end up with a GT1749V / GT2052V hybrit, an GT2056 or even an GT2556V, as i have experience with the turbo and they are cheap to buy. I also think about the manifold, if i should use the stock manifold or use the one, i have used on the AAZ engine.

The benfit of VTG are to high to go forward with wastegate turbo's for me. With wastegate's you have either big lag or big power restriction and high egt's or you need a perfect turbo and are willing to go 2,0 bar or more at high rpm's. The other benfit of VTG turbos is the more easy package, because you do not need external wastegates.

Regarding my swap, yesterday everthing seems to be clear and i was willing to take over the whole package including the hole electronics, but now i think again if mtdi could be more fitting to me. I like the idea of being in full control for fuel with a screwdriver and 13mm spanner.

As summary the hole engine build is not fixed in my head. What is for sure is that i will rebuild the head, use a regrinded camshaft, go back to organic sachs performance coupling and will use a bigger VTG turbo. The pump will 11 or 12 mm plunger with AFN camplate and i have no idea what nozzles to use. I like to have to the pump, turbo and nozzle be ready for 200hp+ and will be happy with everthing above 180-190 hp.


Best Regards
Alleslowbuged   

   

14
IDI Engine / Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« on: December 08, 2016, 05:59:40 pm »
Hi,

the guy did not call me back and i do not get him back to the phone in April, so nothing happend until now. But today i buy an Golf MkII with an AFN engine, and bring it to my garage. I will use the engine the electronic from the new golf for my red golf, so my TD will get an TDI.

Best Regards
Alleslowbuged

15
IDI Engine / Re: Golf II GTD with 1.9 AAZ engine --- EVO II
« on: April 24, 2016, 03:49:06 pm »
Hi,

i have had a phone call regarding the AFN Package and i think i will buy it (to be honest, i send him a message that i will buy it). The guy offers tdi engine swaps as his job and the golf, where the engine is actual in, is also done by him (customer car, not his own). Because i have realy little to no time, i play with the tought to bring him my golf and let him change the complete package. I also asked him, if i could buy the hole car, but he still needs some parts (it is a golf syncro). I wand to avoid to speak from a "complete package" and afterwards spend hunderts of euros for a few small OEM parts, because this and that is missing, to make it running again.

Best Regards
Alleslowbuged 

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