Author Topic: IDI to TDI (Read 52634 times)

rallydiesel · « **Reply #45 on:** December 13, 2007, 03:46:47 pm »

What are you doing injection pump-wise? Are you getting the IDI injectors shimmed to open at the TDI specs? What did Giles say about using an IDI pump to pump at TDI pressures?

Slave2School · « **Reply #46 on:** December 13, 2007, 03:47:44 pm »

idi injectors do not fit in the holes.

rallydiesel · « **Reply #47 on:** December 13, 2007, 03:51:35 pm »

So are you bumping the TDI injectors down to IDI levels or bumping the pump up to TDI levels or using a TDI pump with an IDI top half or what? This project will be incredible if it works!

jimfoo · « **Reply #48 on:** December 13, 2007, 03:57:11 pm »

Sounds like Giles will be using the TDI pressures with TDI injectors. Hopefully mine will clean up ok as it sounds like they have jelled veggie oil in them. They have 205 nozzles, which should be fine for what I need.

rallydiesel · « **Reply #49 on:** December 13, 2007, 04:42:47 pm »

So he will use the 1.9 IDI pump then?

jimfoo · « **Reply #50 on:** December 13, 2007, 07:48:28 pm »

Yep, 1.9 IDI pump with a 10mm TDI head I already bought and possibly using the IDI cam plate as I'm not after huge power. But he will see how it works and adjust accordingly.

jimfoo · « **Reply #51 on:** December 14, 2007, 10:54:21 am »

One new thing I discovered about the head is that if I tighten the 5th cap down, I can no longer rotate the cam by hand, so it will have to be reamed/bored a tiny bit. None of the rest seem too big, so luckily nothing major.

jtanguay · « **Reply #52 on:** December 17, 2007, 12:08:37 am »

Quote from: "prothe"

I think the problem with a 1.9 IDI to TDI conversion is that the TDI piston will stick too far out of the top of the block. I don't have my piston book with me, but the distance between the pin and the top of the crown was different on the AAZ and 1Z pistons. That is why I am not pursuing that conversion. If I am wrong, let me know.

What I am pursuing is a 1.6 to TDI conversion, because I found a piston that will fit the 1.6 block. This is on paper only... I have ordered the piston, but it has yet to come in. My plan is to then put a stock 1z head on the 1.6 block. I know there are some cooling hole issues that I haven't looked at. Setting the compression to about 18:1 (I forget the ideal number) will also probably have to be addressed.

The 1.9 AAZ engine could be made into a 1.6TDI with cylinder sleeves. (assuming I am right about the 1z pistons being too tall).

I don't want to mess with injector pumps, so I will probably lower the opening pressure of the TDI injectors to suit the older pumps. If that doesn't work, I will have to upgrade the high pressure side of the 1.6 pumps. I want to try to keep the price down.

The intake and exhaust will be unchanged.

I wish I could make better progress on this project, but getting the pistons has been really slow, and I don't expect them for another 2 months.

are you factoring in rod length to measure piston protrusion? i think it'll be fine if 1Z crank + 1Z rods + 1Z or even AHU pistons are used. maybe if AAZ rods are used the pistons will stick out too much, but even still we need to see it put together and real world numbers. hopefully jimfoo can measure piston protrusion for us

i think 1Z tdi's are around 190 bar injection. was there a reason for higher breaking pressures on the ALH? the older pumps should be good for 190 bar injection and i wouldn't settle for anything less than stock, as it could affect a lot.

just curious, but how much can you have a block sleeved for? is it really that cheap? i heard it was a bit complicated with freezing the block to shrink it for a good tight seal?

jimfoo · « **Reply #53 on:** December 17, 2007, 12:39:39 pm »

From what I can tell without the pistons in the block, they are almost identical in height. If anything, the TDI pistons are ever so slightly shorter.

jimfoo · « **Reply #54 on:** December 18, 2007, 06:19:47 pm »

Well I completely tore the engine down today. The crank sprocket still looked good though I am putting the TDI one on it. The crank and rod bearings didn't look too bad considering the time I ran out of oil. The intermediate shaft bearings seemed fine, so I will leave them but put in new rod and crank bearings. So I think I will bring it down to the machine shop tomorrow for boring, balancing and head work. I decided not to get the pistons coated as I would have to send them out and I want to get it back together asap. After that I will get the $ and send the pump and injectors to Giles.

jimfoo · « **Reply #55 on:** December 18, 2007, 11:25:16 pm »

Yep, I will be getting it balanced. From what I can tell, the TDI pistons are only 3.2 grams heavier.

jimfoo · « **Reply #56 on:** December 20, 2007, 08:18:58 pm »

I brought the block, head and new pistons down to the machine shop today. I told him what I was doing and to double check the AAZ components in the TDI head to make sure they would work, and to double check the piston height. I am getting it all balanced I asked him about coating the pistons, and he said there is a local place that does good work, charging $20/piston, so I will get them coated after all. I still need to order the TDI crank sprocket as they are going to put it on as well. Now to get the money for the Giles pump! :twisted: :twisted: :twisted: :twisted:

jimfoo · « **Reply #57 on:** December 21, 2007, 02:24:13 pm »

The machine shop called today saying the head is done. All the AAZ components will work in the head, cam, valves, springs, lifters. SWEET!!!!

jtanguay · « **Reply #58 on:** December 21, 2007, 03:33:49 pm »

Quote from: "jimfoo"

The machine shop called today saying the head is done. All the AAZ components will work in the head, cam, valves, springs, lifters. SWEET!!!!

thats crazy... will the IDI cam have the right lift for the TDI engine though? if it did that would be totally awesome...

soon to come, convert your 1.9 IDI to TDI! :twisted:

jimfoo · « **Reply #59 on:** December 29, 2007, 10:25:44 am »

I don't see why not. Same displacement. I got the head, but have to bring it back as someone dropped the ball and didn't resurface it though they charged me for it. Right now you can easily feel and see the machining grooves in it which makes me worry. He said they can put a mirror finish on it if I want. I have started ordering other basic parts like bearings and seals, and have ordered the crank timing gear. Other than the gear, the block will be done next week. I will get pics once I get everything back.