1.6 mechanical block with 1.9 hydrolic cylinderhead.."V - page 2 - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• #15 by Powered by Spearco on 28 Jan, 2009 20:37
• I smoke tested and presure tested the cooling system passages at 20 psi. today and no leaks to speak of.   .
• #16 by Rabbit on Roids on 10 Mar, 2009 00:02
• Quote from: "zukgod1"

  It will be just fine.
  
  I did it long ago and works just fine.
  
  I'll be in PDX in June on vaca. I'll drop ya a line before I take off, maybe I can stop in and say hi..

  
  
  hey, if im still around when you come to portland.. i want to see your car. i drool from looking at it.
• #17 by zukgod1 on 10 Mar, 2009 08:25
• Quote from: "Rabbit on Roids"

  Quote from: "zukgod1"

  It will be just fine.
  
  I did it long ago and works just fine.
  
  I'll be in PDX in June on vaca. I'll drop ya a line before I take off, maybe I can stop in and say hi..

  
  
  hey, if im still around when you come to portland.. i want to see your car. i drool from looking at it.

  
  
  I'll be in a 2002 Passat for that run. Going to have the whole fam damly with me, need comfort!!!
  
  Still planning on coming up in June though.
• #18 by one_tinted_tail on 10 Mar, 2009 09:23
• what timing, I was just going to post about using a 1.6hyd cyl head with my 1.6TD mech block..
  
  So it has and can be done?
  
  Was it just the extra oil line that was plugged? what material did you use to plug it? is it reversible?
  
  whats with the other small rubber looking piece wedged in the HG? the picture I see doesnt look sealed. I dont imagine its just there to keep things in place since youre using studs...
  
  would the 1.9 crush HG still be compatible?
  
  nice clean work by the way, thanks!
• #19 by saurkraut on 10 Mar, 2009 12:01
• An aluminum pipe plug works:
  
  
  
  
  More at:
  http://www.vwdiesel.net/forum/index.php?topic=15780.0
• #20 by zukgod1 on 10 Mar, 2009 12:34
• I welded mine and plugged the hole in the block as well then placed a piece of rubber over the void in the gasket.
  
  
  
  
• #21 by one_tinted_tail on 11 Mar, 2009 09:27
• looking over those first pics reminds me to fit a different valve cover,mmmm..
  
  
  nice job zuk, i was kind of hoping for something less than permanent for myself.
   theres no pressure at that hole, so it really just needs to be sealed and I'd prefer it at the top so oil doesnt pool for weeks, months, years then finally let out a potentially hazardous chunk..
  
  thats it though right? all the other passages are identical and compatibility with the 1.9 HG is non issue?
• #22 by zukgod1 on 11 Mar, 2009 11:16
• Ya, aside from the oil drain and the coolant passage everything else matches up.
  
  You may want to consider drilling the extra steam passages that the AAZ head gasket provides. You don't have to but better cooling is always good.
• #23 by one_tinted_tail on 12 Mar, 2009 11:27
• dealaing with the oil passage now,
  
  can you give details on the coolant passage? I saw it mentioned in some threads i was reading but nothing specific. was it the head or block or gasket needing to be addressed?
  
  ..& ive always thought it curious that so many VAG HG's are prted the way they are.
  
  thanks
• #24 by Powered by Spearco on 14 Mar, 2009 18:16
• Well, today was the day it came together.
  Got the rest of the exhaust made up from the down pipe. Except its now
  2 1/4 tubing. Turned out nice I think.
  
  Here it is on the truck.
  
  
  First start up was really smoky. Really smoky. Pump timming is at .98
  and the pump came off of the other motor on the truck. I think that the pump is due for a rebuild soon. Oh I forgot to say that there is a set of SMOG GTD nozzles in and set to 155 bar. Here look at this.
  http://[URL=http://s232.photobucket.com/albums/ee10/joshmarstall/?action=view&current=CLIP0744.flv][img]http://i232.photobucket.com/albums/ee10/joshmarstall/th_CLIP0744.jpg[/img][/url]
  I did turn down the fuel screw a 1/2 turn and seemed to help but was at running temp. So will have to wait to see if it needs any other tweeking.
  Yah the bolck heater didn't help either on first start.
  Heres  another vid after the pump was readjusted.
  http://[URL=http://s232.photobucket.com/albums/ee10/joshmarstall/?action=view&current=CLIP0749.flv][img]http://i232.photobucket.com/albums/ee10/joshmarstall/th_CLIP0749.jpg[/img][/url]
  
  Also when taking it for a test drive, I knoticed the turbo was quite louder and has that sound others were talking about. Sound tough I think.
  I wasn't really throttling it very hard, but got to 6 maybe 8 PSI and about 800 to 1000 EGT's. The smoke seems to deminish at above 3K RPM. Maybe I should add a lift pump. That might help with the smoke at idle?
  http://[URL=http://s232.photobucket.com/albums/ee10/joshmarstall/?action=view&current=CLIP0750.flv][img]http://i232.photobucket.com/albums/ee10/joshmarstall/th_CLIP0750.jpg[/img][/url]
  http://[URL=http://s232.photobucket.com/albums/ee10/joshmarstall/?action=view&current=CLIP0751.flv][img]http://i232.photobucket.com/albums/ee10/joshmarstall/th_CLIP0751.jpg[/img][/url]
  
  Please any thoughts or ideas.
• #25 by burn_your_money on 14 Mar, 2009 18:52
• How old is your fuel? My jetta is smoking white like that right now and the fuel is probably over a year old. When I was initially running the motor off a jerry can it did not smoke.
  
  With the lack of the extra oil passage it might be a good idea to add the extra CCV system that the AAZs have. I'm thinking that with high boost pressures you might get some significant blowby
  
  How old are the injectors? I've noticed a couple times that new injectors clack more then old ones.
  
  That's a sexy truck by the way.
• #26 by Powered by Spearco on 14 Mar, 2009 19:09
• The fuel is less than a month old and the injetors are basicly brand new. I know that theres alot of unburnt fuel being thrown out. Thats where all the smoke is coming from. No cross contamination in oil or coolant so far.
  Man those Air Craft Spruce thermo couple really reacts fast. I like it.
  I'm wondering if I should advance the pump timming to 1.05 and see if it  helps with the smoking.
  As for the CCV, You can see that I have it routed right out under the engine for now  :oops:  :lol: .
  Some little tidying up to do. Like fixing the leaky turbo oil return line where it flex's, getting the valve cover leak at the cap. Replacement is on the way.
• #27 by burn_your_money on 14 Mar, 2009 19:24
• Oh yes, there it is. It blended in with the block too well   :lol:
  
  I seem to recall someone (maybe Dave) saying he needed to advance the pump to around 1.35mm but I could be completely wrong on that one.
• #28 by Powered by Spearco on 14 Mar, 2009 19:39
• Hopefully someone will chime in and give some addvice (Andrew)   , about addvancing the pump
• #29 by zukgod1 on 15 Mar, 2009 20:40
• Advance your timing sir!