mk3 Jetta GT to GTD conversion (and pre-conv rebuild) - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• mk3 Jetta GT to GTD conversion (and pre-conv rebuild) by akrallysport on 14 Dec, 2009 11:33
• Hey guys... I was on the forums a while back but disappeared when I was fixing up my dad's old mk3 Jetta GT to use as daily driver  since mine was rusting out and broke the aluminum alternator bracket. Anyways, I stripped it and scrapped the chassis/doors etc. and kept all the functioning bits. In the meantime, I've been driving around with the ABA gas engine and it just chugs fuel. Instead of trying to diagnose a $$$ sensor problem, I've decided to swap in the 'ol AAZ because:
  
  - economy (I've been used to 5L/100km, but now I'm getting 10L/100km with the gasser)
  - I've spent a bit on the TD by rebuilding the turbo, new clutch, etc.
  
  So, while the weather outside is cold I'll be freshening up the engine:
  - new rings
  - bearings (if needed)
  - ARP head studs
  - HG
  - manual boost control (run it at 12-14psi)
  - IP reseal, maybe some tweaks (considering going 10mm)
  - 1.6TD pin (or machine the current one)
  - GTD nozzles (maybe)
  
  Just a couple of basic questions before I begin...
  1 - What's the best way to clean the outside of the block? I really don't feel comfortable sandblasting it with all the critical faces exposed. Or should I just tape them off and hope for the best?
  2 - Anything else I should do while I'm in there?
  
  Pic of what I'm starting with...
  
  
  
  
• #1 by akrallysport on 17 Dec, 2009 08:10
• Pulled off assorted bits and pieces to give myself a break while studying for finals. I discovered that one of the previous coolant leaks was indeed caused by a leaky injection pump.
  
  Should I be going for a 10mm plunger if I plan on machining the boost pin, GTD injectors and upping the boost, or can I stick with the 9mm?
• #2 by TurboJ on 20 Dec, 2009 06:53
• That'll depend on the power goal. You can go surprisingly far with the stock plunger head, so I would suggest you first try it that way (do the governor mod and see if that takes you where you want to go).
• #3 by akrallysport on 20 Dec, 2009 07:54
• Yeah, I think I'm going to stick with what I have and see... I'm trying to keep it a daily driver with a reliable power boost (stock TDI levels are the minimum).