VWDiesel.net The IDI, TDI, and mTDI source.
Engine Specific Info and Questions => IDI Engine => Topic started by: Digital K on March 08, 2011, 08:37:57 pm
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so several people told me to post a build thread here. I thought i would try. I havent really been keeping track of everything I've been doing this time around. It'll be more of a hey here's what I've been up to with the truck and other *** thread. I'm bored, so this thread will have a lot of initial content.
I am new here. I am sure I know some of you. Here are two of my fav mk1's I've built in the past...
this car had the following motors:
originally a 1.6 diesel. The block cracked, and was literally GLURKING coolant out the side. not good. I wanted to go fast so I installed the following in order:
ABA
1.8 16v
1.8 16v w/ ITB's
2.0 16v w/ ITB's
2.1 ABA 16v w/ ITB's & motronic & weber DCOEs
2.1 9A 16v w/ weber DCOE's
(http://farm4.static.flickr.com/3283/2375326142_64c9c7482b_z.jpg)
(http://farm4.static.flickr.com/3107/2374501499_534bbc541d_b.jpg)
(http://farm3.static.flickr.com/2403/1572788053_ebe44a3579_o.jpg)
(http://farm3.static.flickr.com/2192/2181228884_4623360516_o.jpg)
(http://farm4.static.flickr.com/3009/2956359524_c5204f55bb_o.jpg)
(http://farm3.static.flickr.com/2411/2170445054_619f92237b_o.jpg)
(http://farm4.static.flickr.com/3214/2701531185_e34bfeedb0_o.jpg)
(http://farm3.static.flickr.com/2161/2170453284_fb8de0d752_o.jpg)
This is the car I built for my wife Jes:
here it is when we got it.... we drove it around awhile but decided to maybe just upgrade the motor....
(http://farm3.static.flickr.com/2082/2325172405_a86632c03e_o.jpg)
(http://farm3.static.flickr.com/2418/2325172667_5bac29909b_z.jpg?zz=1)
3 or 4 years later...
it originally had air ride, but I hated it, so we put coils in.
(http://farm5.static.flickr.com/4099/4795417272_6ed705ed09_o.jpg)
(http://farm5.static.flickr.com/4117/4795417300_47b2f85e88_o.jpg)
(http://farm5.static.flickr.com/4141/4791480358_b12369a242_z.jpg)
(http://farm2.static.flickr.com/1308/4709483233_a3454b70e9_o.jpg)
static:
(http://farm5.static.flickr.com/4001/5147170988_c32a23f7aa_o.jpg)
(http://farm6.static.flickr.com/5215/5507579648_08a5b642e0_o.jpg)
here is the engine bay:
(http://farm5.static.flickr.com/4018/4683779595_ef88ee910e_o.jpg)
here is the wheels we have lined up for it this season:
(http://farm6.static.flickr.com/5201/5288907153_5b409321c4_b.jpg)
(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash2/65890_10150371327110111_892870110_16302332_648893_n.jpg)
here is how it sits now... stuff out for powdercoating...
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/168526_10150379005950111_892870110_16491896_1308111_n.jpg)
onwards w/ the story.
I bought this truck last summer. It ended up being kind of a piss with the 1.6 gas engine starting to smoke quite a bit after I started driving it regularly.
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash2/67298_10150302710585111_892870110_15145920_7163576_n.jpg)
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc4/69006_10150303076830111_892870110_15154635_4266941_n.jpg)
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc4/68758_10150310740915111_892870110_15289409_6052254_n.jpg)
here I am bringing the AAZ home...
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc4/75334_10150317894465111_892870110_15404908_4260545_n.jpg)
and some mopeds home...
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc4/77154_10150332331430111_892870110_15662802_3763741_n.jpg)
1.6 8v out!
(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/168709_10150393669680111_892870110_16782029_738339_n.jpg)
the front valence was destroyed by a giant tree stump, or something rather unfortunate. I obtained a repair panel and went ahead w/ the repair...
(http://farm6.static.flickr.com/5001/5371188803_b9cf85a717_z.jpg)
(http://farm6.static.flickr.com/5255/5420714386_e2b73bb50a_z.jpg)
(http://farm5.static.flickr.com/4142/5449704922_0645ec8a50_z.jpg)
(http://farm6.static.flickr.com/5057/5472412433_4a39e60bdc_z.jpg)
aaz about to go in!
(http://www.flickr.com/photos/krisclewell/5443072501/sizes/z/in/photostream/)
in!
(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/181760_10150421722480111_892870110_17221974_935719_n.jpg)
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/189128_10150443165790111_892870110_17482603_4254410_n.jpg)
here is the exhaust from techtonics:
(http://farm6.static.flickr.com/5057/5511299282_c6d002abf8_z.jpg)
here is the DP I made...fits great!
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/185859_10150438261090111_892870110_17419048_2957808_n.jpg)
I have lots of little stuff left to do. but realistically its almost there.
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(http://farm5.static.flickr.com/4018/4683779595_ef88ee910e_o.jpg)
OMFG
I was afraid you were scrapping that and throwing a diesel in your rabbit.
Glad to see the rabbit is staying as a 16V ;)
If the caddy turns out half as nice, it'll be awesome as well!
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That AAZ looks familiar. Was it sitting on the floor of basement in Nashville at one time?
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yeeeesssss it was :)
I also put a TDI Crank and all new bearings in. the crank nose was pretty gross.
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awesome. glad this works. had to make a gasket for it. thin film of RTV. we'll see if it holds pressure. I have to imagine it will.
(http://farm6.static.flickr.com/5296/5511609482_71aecdf581_z.jpg)
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Glad to see you posted up Kris ;)
Welcome aboard the Soot Train lol
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yo
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Hey Kris,
I know how hard aaz stuff is to get down your way. Thunder Bay is 45 mins from MN, and the local dub dealer here is pretty good for shipping. If you want, let me know what you need, and I'll try to get it shipped off to you. I make trips to Grand Marais every so often, so I can ship it from the Post Office there.
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That coolant flange is supposed to have a 3/16 oring
Ace hardware will have them
GB
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yeeeesssss it was :)
I also put a TDI Crank and all new bearings in. the crank nose was pretty gross.
Did you pull the crank and take it to a machine shop, or do it yourself somehow?
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wellllllll this *is* a diesel thread, but I'm not a purist, so any nice work is welcome in my book. Nice work. I've got a spare parts car comin' my way, that if the body's straight and rust free, I might just rebuild. I must say this has motivated me somewhat.
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yeeeesssss it was :)
I also put a TDI Crank and all new bearings in. the crank nose was pretty gross.
Did you pull the crank and take it to a machine shop, or do it yourself somehow?
I pulled the old crank, and threw it in the garbage and put the TDI crank in. I was told this was ok?
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I'm sure the work being done on the caddy will be no less then the work done to your other bunny's. I never knew (audrey was it) had the canvas top. Love the new slippers for the green one!
What's all your plans for the caddy/aaz?
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almost done :)
plans are to intercool and to boost once I get it running. Once all THAT is sorted out, I'll probably pull the motor and repaint the bay, and the truck....and clean the motor up.
(http://farm6.static.flickr.com/5011/5562773164_2fe639caa2_b.jpg)
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Excellent!!
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I remember seeing these cars on vortex, amazing work on all three, especially the "wife's" car lol.
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Nice work. My td caddy is mojave beige (a color I never really loved) just like your gasser rabbit, and I must say that's one of the first times I have seen one look good in that color, it just sits right. The aaz caddy build looks good, too!
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many exciting wiring surprises like this today:
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/196836_10150468936445111_892870110_17759943_2244357_n.jpg)
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many exciting wiring surprises like this today:
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/196836_10150468936445111_892870110_17759943_2244357_n.jpg)
Well I guess you get to go on a witch hunt for quality wiring.
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Whats so exciting about that? Looks like every VWs MK1 or MK2 butchery.
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Exactly. If that makes you worried than you don't want to look in my engine bay! :o
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Whats so exciting about that? Looks like every VWs MK1 or MK2 butchery.
sarcasm.com :P
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Exactly. If that makes you worried than you don't want to look in my engine bay! :o
Feel you there man! I use all the same colours for all my wiring too... I mean for me its easy to diagnose... But I fear for the next SOB lol
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So if that one connection looks spooky, what does the radio wires look like.
Everyone and anyone who has owned or even ridin in a MK1, 2 or 3. The radio wiring is the first to get hacked. Just saying.
By the way, your truck is looking good, and if you build all you rides the way you built your Rabbits then the truck will probably look the same.
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dropped the pump and injectors off for a rebuild. it leaks. may call and just have him reseal it instead. It worked ok otherwise, and this is just costing too much at this point...
(http://farm6.static.flickr.com/5022/5626666952_6e7c3bd91f_b.jpg)
put a hone on the block w/ new rings in new to me pistons.
(http://farm6.static.flickr.com/5302/5623479883_5bae48cf45_z.jpg)
saga almost over. ::)
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update.
running 22 psi at the moment. goes pretty good. I wish it was faster.... I really think I could benefit from a governor mod, as the fuel tapers off. dont have the fuel to run more boost. I do not want to pay the money for a giles pump. I just dont see how its worth 1000$ . So. It is what it is right now :) I have the 1.6TD boost pin. Im having issues with boost piping coming apart. I ordered all new couplers in black.
I need a tach. where do I get the signal off of the alternator on these? what kind of tach do I need to accept the signal?
Here is the current setup. I realize the coupler is incorrect. hopefully the 200$ in couplers I bought will help line things up straight and narrow.
(http://farm4.static.flickr.com/3557/5774732558_93c4be9cc7_z.jpg)
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Tach sig is from the Alt. Being an AAZ, it should have a W terminal on it right? Get an '83-'84 GTI cluster and mod it to work.
Do the GOV mod yourself. Its not that hard to do. Theres lots of write ups here on the board.
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Tach sig is from the Alt. Being an AAZ, it should have a W terminal on it right? Get an '83-'84 GTI cluster and mod it to work.
Do the GOV mod yourself. Its not that hard to do. Theres lots of write ups here on the board.
I cant run that cluster in the truck. its an early westy and just has this:
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/248467_10150646184720111_892870110_18768378_274336_n.jpg)
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Playing with fire without that timing cover.
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Dayum! That is all. I love all of them!
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Playing with fire without that timing cover.
^^^^^^^^^^^^^^ = TRUE
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Playing with fire without that timing cover.
Mine didn't come with one. What're the risks? Just having it come off?
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Having what "just come off"? the belt??
You got huge problems if that happens..
However I am being a tad hypocritical... I don't run one either... Chances of a rock breaking the belt are prob around the same with the cover on lol
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Playing with fire without that timing cover.
Mine didn't come with one. What're the risks? Just having it come off?
If it comes off, you're rebuilding at a minimum your head and are probably putting in a bunch of new valves, possibly lifters and a cam too.
Since it's exposed, any sand/dust/water/mud you may happen to drive through will find its way between the belt and the pulleys and into the tensioner wearing everything out faster than would happen otherwise. I don't mean driving around on the beach, I just mean stuff on the road or whatever. If the recommended change interval is 60,000 miles for a protected belt, I'd imagine the change interval for an "exposed" belt would be much less!
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Sand, dirt, particles what have you.. All can still get in the belt housing. It is no sealed.. As matter of fact if you take a look at the back of the cover there is a clear open hole that anything smaller than a golf ball could fit through :o.
The cover does NOT protect from dirt and water.I repeat does NOT protect from dirt and water
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Rocks and sticks? A little bit.. How often do these things fling up in to the engine bay? And when do you honestly drive over long branches that will go up and take out the belt??
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I just took mine off and you could eat out of the timing cover area it was that clean. I think it does great for protection of sand/mud/water. It is not 100% sealed, but mine doesn't have a golf ball opening either? The only thing I could say is that the belt exposed you could see if it was getting eaten "slowly" but I put a plexiglass window in my cover so I don't have the dissadvantage of not being able to see the TB. Also, if something like the metal that holds the mat on the hood wants to come down and rub up against the TB then it is a bad day.
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libbybapa had a story about a customer who left it off, and a plastic grocery bag got sucked up into it and it popped.
Also, and a recent story here (or www.vwdieselparts.com forum) where someone popped their belt because of no timing cover. Had to pull the head.
Ah. For your reading pleasure.
http://www.vwdieselparts.com/forum/viewtopic.php?f=8&t=10687
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Gov Mod in my sig.
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I've also seen stock motors throw a rod under normal use. If it's gonna happen its gonna happen. Karma man, Karma.
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Not diesel related, but VW interference related. I used to have no upper or lower cover on the 16v rocco. On a drive back from Cali to Wa, I was passing a logging truck, a piece of bark got caught between the belt and the pullies. Car stopped running. We (I was caravaning) went and got a new belt (super easy to install with no covers) and yup, 3 bent valves. Car was towed to Eugene and sat for 2 weeks before I could get a trailer down there to bring it back to take the head off and replace the bent valves.
All that said, the diesel rocco only has the lower cover and the previous rocco now has a lower cover ;)
Yes, I live my life a quarter of a mile at a time :P
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Tach sig is from the Alt. Being an AAZ, it should have a W terminal on it right? Get an '83-'84 GTI cluster and mod it to work.
Do the GOV mod yourself. Its not that hard to do. Theres lots of write ups here on the board.
I cant run that cluster in the truck. its an early westy and just has this:
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/248467_10150646184720111_892870110_18768378_274336_n.jpg)
Use a non-C model cluster with tach. AKA Scirocco. mod the tach so it works with the W terminal output from the alternator.
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I am not suggesting that anyone run with no covers at all. Just pointing out my experiences with no covers ;) Tolerances on the diesel rocco do not allow enough room to run an upper cover. Yes, I know, its dangerous. I check the alternator belt religiously :)
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Im aware the motors are interference. The AAZ covers dont fit. irony is I dropped a washer into this motor in specific and bent every valve in the head. it now has a completely rebuilt head, new pistons, and new rings.
I also dont have any vbelts.
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Im aware the motors are interference. The AAZ covers dont fit. irony is I dropped a washer into this motor in specific and bent every valve in the head. it now has a completely rebuilt head, new pistons, and new rings.
(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/205210_10150555020215111_892870110_17901705_3789498_n.jpg)
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(http://www.nonwovenmasks.com/pic/20105894422.jpg)
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never
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Its your supple skin that the girls will pine for :P
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Im aware the motors are interference. The AAZ covers dont fit. irony is I dropped a washer into this motor in specific and bent every valve in the head. it now has a completely rebuilt head, new pistons, and new rings.
I also dont have any vbelts.
I prefer learning from my pain. I'm sure I wouldn't have any trouble making the timing cover work even in a mk1. It would be a heck of a lot less work and far less painful than replacing all the valves... again...
FWIW, your engine will also work without an air filter on it...
razor blade + 45 seconds = late plastic cover working with a mk1 mount
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Tach sig is from the Alt. Being an AAZ, it should have a W terminal on it right? Get an '83-'84 GTI cluster and mod it to work.
Do the GOV mod yourself. Its not that hard to do. Theres lots of write ups here on the board.
I cant run that cluster in the truck. its an early westy and just has this:
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/248467_10150646184720111_892870110_18768378_274336_n.jpg)
oh,...
well then:
http://forums.vwvortex.com/showthread.php?5319913-lt-FS-gt-Early-Gauge-Clusters-(1-Black-1-Woodgrain)
I know you hate wiring but they are cheap and I don't see these often.
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Those are ridiculously cheap!! If I didnt have so many that I have been hoarding, I would buy them just to have them! Kris, get the black one!!
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I have a couple ;)
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I prefer learning from my pain. I'm sure I wouldn't have any trouble making the timing cover work even in a mk1. It would be a heck of a lot less work and far less painful than replacing all the valves... again...
FWIW, your engine will also work without an air filter on it...
I take it you have one that you can send me for free? The one I had was in many many pieces. Let me know if your condescension translates to altruism.
redid all the intercooler piping today. feels good.
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/246778_10150653136360111_892870110_18852721_2504179_n.jpg)
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Rad.
Looks good. When can I get a ride? ;D
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WOW!! This is the internet. The stones we throw here fall far short of our targets.
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God I love your writing skills and sentence structure Andrew. Seriously. No offence.
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I do not want to pay the money for a giles pump. I just dont see how its worth 1000$.
Totally worth it IMO, and I've ridden in a few 1.6s with DIY governor mods that did not impress me as much. It really wakes up the car. Not doing a Giles pump in a IDI is like not chipping a TDI or 1.8T, and you know how that is. The $1k is not just for performance gain, but also for a fresh pump rebuild that'll last another 250k miles or so. Bio-diesel resistant seals too. Ugh I sound like a salesman, but I like his stuff.
Cool project!
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tdiclub/vwvortex all up in here. ::)
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^ I second what Malone said. Go with the Giles pump & you'll get what you want. Nice project!
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i would say on an aaz it is not as important, aaz already has the better camplate, but theres a lot to a giles pump, there are so many variables with the dynamic timing, amount of fuel injected, the duration of the injection, and apparently hes got a formula that really works. unless you already need a rebuild or you're really looking for performance its not really necessary, and i don't think you're really that worried about it since you have a stock intake manifold and such
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IF I ever need a pump rebuild I'd do it through Giles no question. What you get back from him is a whole lot more than a resealed pump with the governor tweaked! Jezzie got a new (!) pump just before I bought her so I doubt I'll be doing anything in that department for a long time.
Typical pump reseal is about $400 or so if you have a Bosch shop do it, and you get your same old worn out parts back. $1k with Giles gets you fresh internals plus a pump with:
- Boost enrichment tuned for your engine (you tell him what you are running, IC, etc, he will set up the LDA with the proper spring, etc)
- Dynamic timing re-curved (lots more advance - stock advance curve injects fuel way too late at high RPM)
- Pump is balanced so all 4 cylinders get exactly the same metering
- Governor actually PROPERLY tuned for high RPM rather than just some shims jammed in there
- Upgraded cam plate on the 1.6 engines
- Tuning assistance by Giles :)
It's a lot of coin, but it's certainly worth it.
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IF I ever need a pump rebuild I'd do it through Giles no question. What you get back from him is a whole lot more than a resealed pump with the governor tweaked! Jezzie got a new (!) pump just before I bought her so I doubt I'll be doing anything in that department for a long time.
Typical pump reseal is about $400 or so if you have a Bosch shop do it, and you get your same old worn out parts back. $1k with Giles gets you fresh internals plus a pump with:
- Boost enrichment tuned for your engine (you tell him what you are running, IC, etc, he will set up the LDA with the proper spring, etc)
- Dynamic timing re-curved (lots more advance - stock advance curve injects fuel way too late at high RPM)
- Pump is balanced so all 4 cylinders get exactly the same metering
- Governor actually PROPERLY tuned for high RPM rather than just some shims jammed in there
- Upgraded cam plate on the 1.6 engines
- Tuning assistance by Giles :)
It's a lot of coin, but it's certainly worth it.
I would feel much better about it if I saw before and after dyno numbers....
found out the car is quite a bit faster than a mini cooper S yesterday :)
on the timing cover note, I did inquire at the dealer awhile back to get a non broken one. they seem to be NLA? If I found one Id probably find a way to get it on, but im not going to NOT drive my truck in the meantime.
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tyler did a before and after dyno on his na mk2 i believe. i think he gained like 20 hp and atleast 10hp through out the power band
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91 Golf NA. Stock run plus a stock+Giles pump run
(http://img.photobucket.com/albums/v603/burnyourmoney/StockVSPerfpumplegend.jpg)
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See, Kris? It really is worth it ;)
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the difference was the fuel pump.. thats it..
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1000 bucks for 10-20hp? eek. I dunno about that....
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That is on an N/A...There is probably nothing else to get you 20 hp on an N/A. If you wanted to mod more after that then it would yeild even more.
AND the N/A pump is not 1000.00 it is more like 650 IIRC. My TD pump was 900.--
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Someone really needs to do a full write up on just what's possible with a 1.6td or 1.9 aaz with some good mods + Giles pump. Once my project's done I'll try to document it all.
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Over on the Vortex, I once asked what the 1.6 was capable of (http://forums.vwvortex.com/showthread.php?4993878-1.6-TD-max-power)... This was one of the answers I got:
(http://i94.photobucket.com/albums/l83/935racer/DaveCrossDyno.jpg)
Giles pump, as well as lots of other goodies, were involved...
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That is on an N/A...There is probably nothing else to get you 20 hp on an N/A. If you wanted to mod more after that then it would yeild even more.
AND the N/A pump is not 1000.00 it is more like 650 IIRC. My TD pump was 900.--
$700-750 at last quote from Giles. He's on the list, he may chime in.
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Not a fan of low riding cars, but those 2 are beautiful.
Is the truck for sale???? Swore I saw it on the Samba or something....
Say safe, stay well. Jimmy.