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Topics - rodpaslow

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mTDI Mechanical TDI Conversions / New to me 300 tdi pmp
« on: January 20, 2016, 10:56:58 am »
I've got a new pump for my alh and I want to change seal before installing it.  I know they some with a tapered mount for the timing gear and I have to pull this off to replace the front seal.  I'm just wondering how to re-install the timing gear mount.  Since it's tapered, does it need to be pressed on an amount so it stays in place?   Or mark the shaft before removing so you know approximately where it was and press it back on to that mark?  (not talking rotation wise, but length along the drive shaft)

I have one other quick question, what's the best way to drain the coolant in an alh?  Just pull the bottom hose?

mTDI Mechanical TDI Conversions / 2001 Jetta ALH
« on: January 07, 2016, 11:12:30 am »
I've moved up to a newer car with an ALH in it.  I have one question as I'm not-so-good with computer controlled cars.  I a 99 Golf with a 1Z or AHU that is mtdi that is a blast, and easy to fix any issues.  How does a ALH car respond doing away with computer controlled pump and installing a mtdi.  I will likely get rid if the egr stuff as well - cooler and egr system.  Will the glow plugs, speedo, tack, etc work if a mtdi pump is installed?


MK3 Golf/Jetta and B3/B4 Passat / Clutch
« on: December 08, 2015, 04:01:23 pm »
I have had a mishmash of clutch parts I bought online - flywheel, pressure plate and friction plate.  I had a problem and the teeth on the flywheel, about 9 of them were broke off.

I had a spare flywheel, a proper vw replacement (SMF), but of course the friction surface is smaller than the friction plate and pressure plate.  This is a proper clutch setup with flywheel bolts to engine, not the early style.

I know the larger sizes as they are all over the net 228mm seem to be popular.  I need to know what the smaller sizes were as the friction surface on the flywheel I have will work with sizes under 222mm .   Did they come in 220 & 215mm sizes?  I actually order a 215mm and today I get to see if it was the right one....

IDI Engine / Oil catch can
« on: November 16, 2015, 04:02:27 pm »
I have viewed several on here and on line - I have 1 question.  Why do almost all have a breather to the valve cover or block?  Most show a breather feeding the engine(from intake or separate little filter) and the oil catch can is separate allowing the blow by and other thought pcv an being pulled by vacuum back into the intake.  Does a diesel need that breather?  My current setup on my older car goes from the puck to the provent or catch can back into the intake.  Am I missing a breather that should be somewhere in the valve cover?  I'm planning o adding one to my TDI, but I'm not sure how to do it properly?

mTDI Mechanical TDI Conversions / Hesitation
« on: November 09, 2015, 11:18:07 am »
My car, a 1.9 tdi Golg with a 2052 turbo and modded 1.9 pump body with all 11mm internals from a Land Rover (I think it was a LR 300).  It's running very well most of the summer except for hesitation under mid to light load.   If I roll on the throttle from 2000 rpm fairly fast it doesn't do it, but if I back off slightly it will start to sound like it's missing.  I've got .250 Hflox nozzles, new this spring and it's got a lift pump feeding the pump.

I have some smoke under full throttle (I thiink it's okay -maybe LDA needs to be backed off a bit).  I do have the governor mod with this pump as well.

I'm just needing some direction - this hesitation - will timing make a difference or is it likely a pump setting that's off?

Any help in heading the right direction is apprecieated.

mTDI Mechanical TDI Conversions / Swap to larger injectors
« on: April 06, 2015, 02:35:55 pm »
I've just had time to swap in a cheap SDI intake and larger injectors (hflox .25 for original 1Z).  This car has a 2052 turbo in it - it was pretty fast at pump maxed out the the original injectors. 

The one thing I'm not 100% sure about re-stetting the pump for these injectors (not worried about smoke amount) is how much to turn the fuel up to?  Basically turn it up so when the turbo is doing it's thing it's mostly cleared up the smoke out of the exhaust?

Any tips anyone might have?

TDI Engine -General Info / Oil filter relocation
« on: February 02, 2015, 11:02:39 am »
I wasn't sure where to put this.

I added a filter relocation kit and just wanted to note engine oil temperature.  I added a perma-cool kit, but I used single braid hydraulic line and fittings (didn't use the light hose the kit comes with) and moved the oil filter under the drivers side fender (Mk3 golf) so it's easy to change.  I used 1/2" diameter and ran down to the rad cross-member and across, then up about 10" into the fender. (-10 fittings)

I know someone was looking to keep there temperatures down a bit.  With just under 4 ft of 1/2" hose, engine oil temperatures are way down (35 at least) due to the hose helping to keep everything cool.  Oil pressure increased with this too.

I'm not sure what its going to be like in above 0C (above freezing) temperatures, I think cooling with help then as well, maybe not to quite the same degree.

MK3 Golf/Jetta and B3/B4 Passat / MK3 door locks
« on: December 16, 2014, 08:26:25 am »
I have one apart at the moment, the lock part of the door was basically frozen, the vacuum actuator couldn't move it and you couldn't push the lock down either.  I've free'd it and now it moves.  I'm wondering how easy/hard to move can it be before the actuator won't move it?  I don't want to put it in the car till I know it works.

Diesel Swaps / Cruise control
« on: October 29, 2014, 12:17:57 pm »
I thought I'd post this since got it and it's working fine.  If you have a cruise control car and you don't want to have to fiddle with trying to get all vw stuff working again (pump, diaphram for pedal, electronics, etc)-my car someone had tried installing another aftermarket one with a vac pump and rather large control unit that didn't work when I got the car.   I installed a rostra universal cruise in my MK3 golf.  It's a single unit(no vac pump, all self contained) with 7 or 8 wires coming out of it.  I already had the cruise lever in my car (original vw one - open type)  and the rest is a pretty simple setup if your at all good mechanically with a bit of 12v knowledge.  I have a Mtdi in this car and just added a longer lever to the Injection pump and unit has enough pull to easily keep speed or accelerate, no problem.

One note, with the universal don't follow the instructions if your using the w for the tach.  this doesn't need to be hooked up.  Older cars will need a electric VSS or some other speed signal.  My tdi tranny had electronic VSS.

mTDI Mechanical TDI Conversions / Nozzles
« on: October 27, 2014, 02:34:29 pm »
there's not much I can find on what nozzles to use - I know that bigger is likely better as you can always dial it back if needed.  But what is small - I've seen stock is around .187 or so, what is moderate to large? 0.341?

I'm wanting a bit of an increase from stock - would like to hit 200 ft.lb min,  with a 1Z/ahu 11mm head and a 2052 turbo. (in 99 golf-motor & tranny from passat-97)

What would you suggest is a good nozzle for this setup?

mTDI Mechanical TDI Conversions / Injectors
« on: October 17, 2014, 12:32:38 pm »
Can't seem to find this in search - can you swap alh injectors into a older 1Z/AHU engine?  I know they have different break pressures.  Is that any problem for a M-tdi pump? (LR)

mTDI Mechanical TDI Conversions / Idle
« on: October 15, 2014, 12:10:55 pm »
I've read some post in this forum about mtdi idle.  I'd like mine to be a bit higher right around 800-850. If I adjust the fuel screw down and adjust the idle back up it will start to hang at about the same spot every time.  Is there a trick to getting it higher without it hanging?

I've also read a post about injectors.  I know mine need to be changed.  I get some blue smoke at startup and first minutes or so when cold (around 32F, 0C).  Would re-newing/changing nozzles help this and the idle?

TDI Engine -General Info / 1Z Mtdi Boost
« on: August 18, 2014, 12:03:13 pm »
I have a quick question - I have above with a 2252 turbo in it, stock injectors with only 2-3 psi of boost under accel, no smoke at all.  I've turned the pump up as high as I can without it hanging.  Will moving up to .216 (I have in my possession) help the boost issue?

(pump is a bit of a hybrid, 1.9 case with LRover pump internals and head, vw valves from head to injector lines).


TDI Engine -General Info / MK3 conversion to 02A & hydraulic clutch
« on: June 26, 2014, 05:07:23 pm »
I just wanted to make a note, that if you use a 97 (b3-is that correct?) to change into a 02A into a MK3 you don't have to use the passat petals as the clip hole is already there on the plastic Mk3 clutch pedal.  However, the passat hydraulic master cylinder clutch shaft is about 5/8" (roughly) shorter than the MK3 master cylinder is.  So you either have to lengthen the passat one (didn't want to chance I didn't get it right) or get a proper new/used MK3 master cylinder. 

I have used a MK4 golf master cylinder is my other car MK3.  In that case the shaft is a bit too long by about the same amount.  I just made a spacer and was able to use it and the Mk4 slave cylinder.  (much easier to remove line in Mk4 if you need to).


TDI Engine -General Info / TDI & cruise
« on: May 23, 2014, 05:03:29 pm »
I have a 99 MK3 that has cruise (current 2.0 gasser), and I would prefer being able to keep it when I install the TDI.  I know TDI cruise is much different, I don't have the option of swapping it from my parts car as I'm going MTDI.

Would all I need to figure out is where the system needs rpm and vacuum and run these services to those specific places to get it to work, or are there other problems that it just can't be made to work?

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