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Engine Specific Info and Questions => mTDI Mechanical TDI Conversions => Topic started by: jtanguay on April 04, 2007, 08:05:48 pm

Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on April 04, 2007, 08:05:48 pm
Hey guys.  thought i'd post my swap here.  So far so good on tearing down the motor and inspecting it.  I think this is just a testament to the higher grade diesel & motor oil that europeans are accustomed to.

Tomorrow i'm pulling the head, and will inspect the bores, piston tops, valves, etc. the lifters look in really good shape, as does the cam.  i mean, the car only had around 130'000km on it!!!  8)

I will post pictures when i can!!!

edit: i've also noticed that this motor has the coolant glow plugs...  8)
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on April 04, 2007, 10:10:53 pm
Forgot to add some stuff about the EGR and how it kills these motors...  i got an intake from a different car, and man.. this thing is awful!  i cleaned it out quite a bit, but it's still very dirty.  it feels really bumpy on the inside and would definitely account for the buildup of crud.  if only the inside could be polished up real nice! hmmmm...
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on April 05, 2007, 07:17:26 pm
Stupid digital camera... oh well i'm borrowing one for some photo's.

block is stripped and ready for some hot tankage.  going to be giving it a very light hone, new rings, and epoxy paint.

figured that i might as well while it's all out.

still debating how i'm going to go about cleaning the head... the intake ports are all gummed up!  anyone have any suggestions? i've tried this spray on the intake and it worked really well, but there's still a few spots that are really hard to clean.
Title: m-TDI Swap! Into MK2 Jetta
Post by: wolfsburgnut on April 10, 2007, 05:08:59 pm
Paint Gun Wash,  that stuff will strip anything!

Peter
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on April 10, 2007, 07:18:04 pm
Quote from: "wolfsburgnut"
Paint Gun Wash,  that stuff will strip anything!

Peter


is that the name of the stuff?  so far I've just been using a product that is designed for intake / exhaust cleaning and dissolves the carbon.  that stuff is nasty!
Title: m-TDI Swap! Into MK2 Jetta
Post by: 935racer on April 12, 2007, 08:35:14 pm
Quote
Forgot to add some stuff about the EGR and how it kills these motors...  i got an intake from a different car, and man.. this thing is awful!  i cleaned it out quite a bit, but it's still very dirty.  it feels really bumpy on the inside and would definitely account for the buildup of crud.  if only the inside could be polished up real nice! hmmmm...


No EGR's here captain 8)
(http://i94.photobucket.com/albums/l83/935racer/prototypeintake4.jpg)
(http://i94.photobucket.com/albums/l83/935racer/prototypeintake3.jpg)
(http://i94.photobucket.com/albums/l83/935racer/prototypeintake5.jpg)
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on April 12, 2007, 09:19:38 pm
wow! that thing is beautiful!  yep no EGR!
Title: m-TDI Swap! Into MK2 Jetta
Post by: scopefrfd on April 26, 2007, 08:38:42 pm
I have an ALH engine installed in a 92" MK2 jetta.  It's a very tight fit with a M-pump.  The pump is put in an odd forward angle compared to an AHU/1Z engine.  The aneroid gets very close to  the hood/bonnet..so close as to wear away some of the sound insulation.

Stick with the earlier engines if you can...as I had to have a custom adapter plate made for my Fiat 11mm pump,  you should use a late model 2-piece pulley to set pump timing as the ALH injector bracket is designed to have the pump mounted in a non-adjustable manner.  It was quite the pain...but it runs fantastic.
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on April 26, 2007, 09:03:17 pm
thanks for the info!  the pump i have i bought from vdubfun.

(http://img251.imageshack.us/img251/8486/2e1e1um9.jpg)

no LDA... i am thinking that this will pose a huge problem since I am using a much larger Garrett T3 turbo as opposed to the dinky K03.. (more power when boosting, but lots of smoke down low... not good!)
Title: m-TDI Swap! Into MK2 Jetta
Post by: scopefrfd on April 26, 2007, 09:09:32 pm
Your pump looks like it has some modded timing advance...looks like a tdi advance cover..with no LDA to increase fueling under boost...you should look into a K14 turbo.  

I use a k-14 on my m-tdi and it's a great match for what I want.   Lots of torque...I only have .215 nozzles and the k-14 is set for 21-23psi of boost.  A smaller turbo will be much easier to get going or you'll have a smoking pig at low rpm.

I had a callaway turbodiesel with no LDA and it really smoked off boost...but it was the only way to make decent power without a LDA toi help.
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on May 10, 2007, 04:03:10 pm
Numbers for total seal rings!

1.75mm 1st ring

2.00mm 2nd ring

3.00mm oil ring

bore size 79.50mm

The machine shop guy said that there wasn't really any ovaling of the cylinders too... it's starting to look awesome!!!  just need to get a hold of myke_w to get some geotz rings, and ship em off to total seal so i can eliminate blow-by!!!  :twisted:
Title: m-TDI Swap! Into MK2 Jetta
Post by: scopefrfd on May 13, 2007, 12:39:04 pm
I have total seals in my volvo d24td and blowby is virtually non-existent.  The total seal rings I bought from them were actually modified Cofle rings...they still had the "C" stamped into the rings.
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on May 13, 2007, 11:45:49 pm
what is the best way to contact them??? i e-mailed last week... i guess phone now?  :?
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on May 14, 2007, 06:36:40 pm
Quote from: "jtanguay"
what is the best way to contact them??? i e-mailed last week... i guess phone now?  :?


ok well total seal got back to me.  it will cost $50 US for the 2nd rings.
Title: m-TDI Swap! Into MK2 Jetta
Post by: Ziptar on May 27, 2007, 11:06:46 am
Ok, This has got me thinking now that things for my A2 TDI swap have started coming together.

Should I just get a "Good used" engine and drop it in or rebuild a core? The last engine I rebuilt myself without experienced help was a 2 cylinder Briggs and Stratton :-P.

It would be easier and quicker to just drop in and go but, I'd hate to put in the engine only to have a problem 10K down the road.

Roughly what does a 1Z / AHU DIY rebuild run? I'd give it a shot, I have a Bentley  :wink:
Title: m-TDI Swap! Into MK2 Jetta
Post by: scopefrfd on May 27, 2007, 04:27:09 pm
I have a tdi engine that is going to be rebuilt...can build to your needs...PM if interested.
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on May 28, 2007, 07:19:29 pm
Quote from: "Ziptar"
Ok, This has got me thinking now that things for my A2 TDI swap have started coming together.

Should I just get a "Good used" engine and drop it in or rebuild a core? The last engine I rebuilt myself without experienced help was a 2 cylinder Briggs and Stratton :-P.

It would be easier and quicker to just drop in and go but, I'd hate to put in the engine only to have a problem 10K down the road.

Roughly what does a 1Z / AHU DIY rebuild run? I'd give it a shot, I have a Bentley  :wink:


when i got the motor, the intake was gummed up pretty badly from the EGR system.  I want this car to last through some tough winters so I've decided to do it right the first time.  so the head is being cleaned, check for straightness.. see if I need new valve guides and whatever.

the rings will be costing me about $230 or so total, but well worth it since they are going to be total sealed.

for the bottom end you can probably get away with polishing the crank, and new bearings.  

the motor have is from europe and looks good... also the x-hatch in the cylinders is still there, and there seems to be no ovaling of the cylinders, and they look nice and tight.  the motor has around 130'000km.

i could have just installed the motor as is, but the gunk in the intake didn't look too good.. i was affraid of a piece of it falling into my cylinder and doing some bad damage... plus there's probably 5-10 hp worth of power just by cleaning that crap out!!!  :lol:
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on June 01, 2007, 02:28:18 pm
well UPS has done it again!!!

$43.05 customs brokerage fee!!! i just @#$@#in LOVE IT!!!  man these total seal rings better be worth it (i'm sure they are... i just hope that class action lawsuit with UPS goes through and i get some fee's back...)
Title: m-TDI Swap! Into MK2 Jetta
Post by: jimfoo on June 01, 2007, 03:01:53 pm
Guess you should find a friend just over the border who can order stuff for you. Then you just need to "visit" him. No, really, I had those parts on the way down. I was just showing them to my friend.
Title: m-TDI Swap! Into MK2 Jetta
Post by: the4ork on June 22, 2007, 10:56:04 pm
so minus the bogus fee's how much did the rings actually cost you? over $200? didnt think they were that much...
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on June 22, 2007, 11:03:50 pm
Quote from: "the4ork"
so minus the bogus fee's how much did the rings actually cost you? over $200? didnt think they were that much...


yep... over $200 :(  but to me that's worth it.
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on June 23, 2007, 02:20:19 pm
come to think of it, i probably could have bought a custom ring set from them to fit my application, with one of their diamond coated style rings.

i'm sure their rings are as good as goetz, but this is the route i've taken, and i'm sticking with it.  so far hillfolk'r has had very good results!

edit: actually it seems they only have 79.00mm bore rings & 80.00mm bore rings... looks like i would need to oversize to buy their stock rings...  much cheaper buying goetz, than pistons and rings...
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on September 06, 2007, 04:53:15 pm
well project is moving quite slowly... bottom end is all done.

im looking at the autopartsonlinecanada site and it is showing me two different sizes.  7mm and 8mm valve stem seals, and also showing me the option of buying Viton valve stem seals.  is there any benefit to viton valve stem seals???  they only list an 8mm viton seal for the 1Z engine (my engine code is 1Z)

can anyone help me out? i'm guessing that i need 7mm as i'm not oversizing the valves.  if the viton valve stem seals are superior, where can i buy a set of 7mm???

thanks!
Title: m-TDI Swap! Into MK2 Jetta
Post by: vwmike on September 06, 2007, 06:04:02 pm
Most of the 1Z's had 8mm valve stems. You could probably measure to be sure.
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on September 06, 2007, 08:14:12 pm
Quote from: "vwmike"
Most of the 1Z's had 8mm valve stems. You could probably measure to be sure.


ok i'll check.  do you know anything of viton seals?  i'd imagine them to be superior, but not sure.

thanks
Title: m-TDI Swap! Into MK2 Jetta
Post by: hillfolk'r on September 11, 2007, 08:39:05 pm
Quote from: "jtanguay"
Quote from: "the4ork"
so minus the bogus fee's how much did the rings actually cost you? over $200? didnt think they were that much...


yep... over $200 :(  but to me that's worth it.

i found my goetze rings on
mr or m-r or m-r-autoparts.com
(sorry on screwey address)
for around 20-25 a hole!!!!,then the 125 from total seal,yea about 200$
trust me they are worth it
my breather hose exits in the drivers wheelwell over the control arm
theres NO drool everywhere from nasty blowby
no smoke bellowing out,if anything  you put your hand in front of the breather hose,it pulses  air back+forth
thats just the pistons moving up+down in the crankcase  displacing air basically ..
oh my rings cost a little more,cause i had them  modify a 5th set,in case i broke one on installation
they told me that they were so impressed with the (worn out) stock ring set i sent to them for examination,that they honestly didnt make rings that nice
and they would like to attempt  modding a stock(new) set
since the chrome plating didnt chip off the ring when machined(that was their concern),its a good mod to do
my ahu had 8mm valve stems
id stay away from aftermarket valve seals
ive never really seen any problems with valve guide seals on the vws(yea years +years ago),just make sure your valve guide clearance isnt excessive
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on October 23, 2007, 08:10:10 pm
It's been a while since I've posted anything about my m-TDI build.  So far what I have had done:

Block:
- light hone
- new bearings installed
- intermediate bearings installed
- pistons cleaned and installed with total seal rings
- block hot tanked

Head:
- new valve guides
- new valve stem seals
- new gaskets etc
- very light planing just to remove some surface crud built up.
- hot tanked to remove all the EGR crap

To be done:

- clean block for paint (i wish i sand blasted it!!!)
- install new gaskets
- get new oil pan then drill & tap it for a fitting for the bypass filter return
- get turbo fitted up and connect mechanical VNT linkages.
- Install all accessories such as a/c, and alternator.  still contemplating converting to mechanical steering, or just plain running it without power steering.
- figure out the wiring such as temp senders, and glow plug coolant heater setup (probably have something hooked up to the glow plug sensor that shuts them off when the car is up to temp from a re-start)

Now for some pics, because I know everyone here loves pics!

(http://img205.imageshack.us/img205/7039/100_0831copy.jpg)
(http://img205.imageshack.us/img205/9060/100_0828copy.jpg)
(http://img205.imageshack.us/img205/9937/100_0832copy.jpg)
(http://img205.imageshack.us/img205/6350/100_0835copy.jpg)
(http://img205.imageshack.us/img205/2905/100_0830copy.jpg)

Notice on the #2 cyl that I have circled a questionable mark?  looks to me like a nice hairline crack running down a coolant jacket... I'm going to hook everything up and hope for the best on that one.  I really hope it isn't anything serious  :cry:

(http://img205.imageshack.us/img205/8007/100_0837copy.jpg)

Yea its a little painstaking to get rid of the paint on the block.  IMO it will be worth it.  I'll be painting it something nice and bright (maybe even white) so I can detect any sort of leaks, etc.

(http://img205.imageshack.us/img205/8458/100_0833copy.jpg)
(http://img205.imageshack.us/img205/4198/100_0829copy.jpg)
(http://img205.imageshack.us/img205/4924/100_0836copy.jpg)

I wish I could find the pic that I took before of what it looked like; all sooted up.. it wasn't nearly as bad as the manifold I got, but still a night and day comparison.  Worth 5 hp?? 1-3 mpg?  :lol:  

(http://img205.imageshack.us/img205/9369/100_0834copy.jpg)
Title: m-TDI Swap! Into MK2 Jetta
Post by: RabbitGTDguy on October 23, 2007, 09:57:53 pm
very nice...
Title: m-TDI Swap! Into MK2 Jetta
Post by: scopefrfd on October 24, 2007, 08:57:47 am
I definitely have the block checked by a machine shop to verify if the #2 hole is cracked.  It's easy to check now rather than going to all the trouble and finding out it's bad and more than likely ruining the piston.
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on October 24, 2007, 02:13:23 pm
i just called and confirmed with the guy who did the block & head, that he did magnaflux it.  it's just a surface blemish. fewf!   :D
Title: m-TDI Swap! Into MK2 Jetta
Post by: hillfolk'r on October 25, 2007, 09:56:45 pm
better late than never i guess
this is regarding cleaning out the egr crap
i treated it just like an old 2 stroke dirt bike  muffler that  needed to be "decoked"
i used a propane torch and various rifle brushes with good success on the intake
then  back  again with the rifle brushes and a vacuum cleaner
backand forth,,heat+scrape+vacuum
since i was doing  a timing belt at the same time,i pulled the cam and used the torch in the ports too
of course dont get stupid and leave it in there for 15 mins on each port
it made some nasty smoke,but worked good
dont worry about the flames and smoke that shoot back out the port
wear a leather glove and place a piece of sheet metal against the firewall

i also used an air compressor with a blow gun after that
i attached a piece of that hard 1/4 inch plastic line and blew out the ports
 the line could scrape against the walls and help remove more carbon without damaging anything
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on December 12, 2007, 05:09:53 pm
got my injectors done with .216's from Giles :) he said they all popped pretty good so i'm glad.

now its time to slap the head onto the block.  quick question:  can i use assembly lube on the head stud threads?  they say to use regular engine oil.  is assembly lube basically the same? would it change torque values at all?

thanks!
Title: m-TDI Swap! Into MK2 Jetta
Post by: jimfoo on December 12, 2007, 05:47:08 pm
I would think it might change the value, so I'd just use the engine oil and specified value for that.
Title: m-TDI Swap! Into MK2 Jetta
Post by: Baselyne on January 18, 2008, 03:18:59 am
Quote from: "jtanguay"
Numbers for total seal rings!

1.75mm 1st ring

2.00mm 2nd ring

3.00mm oil ring

bore size 79.50mm
:twisted:


IM WONDERING ARE THESE THE RIGHT RING SIZES FOR A 1.6lTD ENGINE?

WHAT DID YOU END OF PAYING, i READ SOMEWHERE YOU HAD TO SEND BACK YOUR OLD RINGS!?

WHAY'S THAT IF YOU DONT MIND ME ASKING!
cheers
Title: m-TDI Swap! Into MK2 Jetta
Post by: jimfoo on January 18, 2008, 09:37:25 am
Those are for the 1.9. The 1.6 has a smaller bore, 76.5 I believe. He sent his rings so that Total Seal could modify his Goetz ring to be gapless. You can just buy their ring set or even the gapless  2nd ring only.
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on December 26, 2008, 12:38:43 am
well long time since an update on this, and i wanted to take some video's & pics of the progress, but i didn't   :(

anyways.. the motor is in the car and it runs EXCELLENT aside from what sounds like possibly a bit too much advance, but i don't mind as long as it won't hurt the motor.  i also bought a kevlar clutch upgrade as i'm sticking with a mk2 transmission for now.  (will go TDI box if i can get one for a decent price)

so far the kevlar clutch needs to be broken in, and can easily be slipped.  i've stuck with the K24 turbo, and can barely build 10 psi with close to, but not even 1000F pre-turbo EGT's without slipping the clutch (gently accelerating-5th gear) so the motor is definitely making the power.  just sucks because it will take about 1000km of driving to fully break in the clutch...

the total seal rings seem to be doing their job as there is virtually no blowby.  i also like the 1.9 block because it has a vent for the bottom end so it won't push the dipstick tube up like on the 1.6  :roll: and considering the rings aren't even broken in yet, it seems to have great compression (although will test at a later date to confirm numbers) as she started on the first catch WITHOUT glowplugs at -3C (weather network, actual temp might be varied) and no lumpy idle, or stumbling!

AT LAST!!! no more rough starting 1.6 engine for me!!!  with glowplugs, the engine starts up sooo smooth... even better than my 1.6 in the summertime!!!  and whats better, is that it seems that the colder the motor is, the quieter it is at idle and even driving.  which also leads me to suspect possibly a bit too much advancement (colder fuel-less timing advancement, or is it the other way around?).

the engine was timed to .90, and on the very first try fired right up with absolutely no hiccups.  truly a first rate build.  i love it when things go right! i consider this a full rebuild minus the bore & new pistons, due to them still being within spec.

the oil is currently being filtered with the FS-2500 bypass filter, and the pressure drop seems to be acceptable - hot idle is around 15 psi. approx 120km on the oil, and on the dipstick it looks the same as it did when it was first poured in.  ANYONE WHO OWNS A DIESEL SHOULD OWN ONE OF THESE FILTERS!!!  i was going to change the oil after 1000km of driving for the sake of the break in period, but now i'm not... i'm simply going to have oil analysis done at a much cheaper cost - about $40 for an oil change (rotella & bosch filter, not even synthetic...), or approx $20 for oil analysis...  the filter system pays for itself after a few years, and will continue to pay for itself just in the way it protects the motor, which was a huge investment for me.  once i switch to synthetic, my oil change interval could be as high as 3-5 years.  which only further increases the savings.  i would estimate bypass filter changes at about 15,000km or more as they are built for heavy machinery dumping crazy amounts of soot into the oil.  they also remove water, a leading cause of acid buildup in the oil  :wink: lets do some math here.  $70 for a synthetic oil change which lasts 5 years, but filters are approx $25, and if changed every 15,000km will add up to 7, and we will add another $70 for synthetic top ups for filter changing for a grand total of $315.  or 20 non synthetic oil changes if you follow the recommended 3 month OCI.  20 x $40(rotella & filter) = $800.  this doesn't even take into account the disposal, the aggravation, frustration, mess, etc.  bypass filter = about $300.  so using the more expensive, and better oil (amsoil or equivalent) you're even saving money than using that okay, but not perfect oil that gets quickly contaminated with soot particles.  so i'll just leave that at that! (that is how i rationalized the purchase...  :lol:) oh i forgot about the full flow filters... they recommend these be changed every 80,000km as i will be using the amsoil EA filter (filters down to 15 microns, and should last to 15,000 without the bypass filter)

i have to give andy2 and his dad a lot of credit to the successful completion of this build (i had them install it - best decision i ever made).  they caught some critical errors which would have completely ruined it.  first, the crank sprocket wasn't fitting snug on the snout (had to be welded up and then filed down-this could have lead to a failed crank bolt eventually) and the engine rebuild shop put in one of the intermediate shaft bearings wrong (some scoring... could have been my installing the shaft and trying to turn it though) the int shaft bearings were glyco, which apparently need to be reamed.  some clevite bearings were installed properly and did not require reaming.  the timing belt tensioner issue was solved by using the steel cover from a 1.9 which used the newer style tensioner, and marking my steel cover, and then notching it out.  simply brilliant! these guys are top notch! i would recommend them to anyone needing work on their diesels. especially getting the crank nose fixed!

i'm going to be taking some video's, as well as popping by Giles' shop to show him how its running.  if this clutch ever holds the power, i'll take it to the dyno  :twisted:  

another thing about this pump...  i asked Giles to give me a retarded idle, but ONLY for idle (for really) and so he did... the idle is pretty quiet... in fact it was more quiet than a passat diesel i heard tonight...  BUT when i'm on the go pedal, it comes alive with all that diesel clattery goodness we've all come to love  :twisted: the main reason for this is so i can let the car idle and not wake everyone up. only when im driving away.. :lol: !!
Title: m-TDI Swap! Into MK2 Jetta
Post by: foxracer1 on December 26, 2008, 10:48:36 am
Sounds awesome long time coming. Lets see pics of it! Vids of it running. How much do you have wrapped up in the build? I plan to do this since my 1.6 needs a major overhaul.
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on December 26, 2008, 12:25:26 pm
Quote from: "foxracer1"
Sounds awesome long time coming. Lets see pics of it! Vids of it running. How much do you have wrapped up in the build? I plan to do this since my 1.6 needs a major overhaul.


i was quoted about $4400 to rebuild my 1.6TD (fully refreshed with new pistons, all new bearings, all head work, but same injectors and same injector pump...)

so i have probably $5500-$6000 wrapped into this build, but its highly worth it.  

payed $1200 for the bare longblock - no accessories, just brackets, w/p, + vac pump

the rest was for
- hot tank & hone block + magnaflux
- polish crank
- all new bottom end & int shaft bearings
- all new seals
- new geotz rings with totalseal 2nd ring (modified geotz ring)

- head planed flat (very very good job)
- head hot tanked to remove EGR buildup
- new guides, seals, lifters, re-used old valves (still in good shape, no contact with pistons)
- ARP head studs - ok this is another thing... the racewares i bought were complete ***!!!!  andrew (andy2) tried torquing them to deform the head gasket, and it wasn't working... he got to about 80 ft/lbs and the gasket was still not squishing, so he went some more and the threads gave out.  COMPLETE ***!!!!!!! ok back on track now  :lol:
- head was pressure tested and ok

- EGT gauge from aircraftspruce
- fs-2500 bypass filter *best investment you could ever make on a diesel
- kevlar clutch with stage 1 pressure plate and lightened flywheel.. it should hold about 150 ft/lbs at least, but for now it can't even hold what my old 1.6 clutch was holding.
- injectors refreshed with .216 nozzles & calibrated/tested by Giles
- and the performance injection pump from Giles. to top it all off.
***forgot to mention that theres misc costs (clutched alt pulley for ex) as well as paying andrew for the absolutely immaculate job he and his father did.  i'm extremely impressed!!!

this morning i went to start it and it chugged, but i saw some air in the lines... so i'll change the fuel filter and possibly rip out the water separator.

now you don't need to go all out like me to have a decent running car, but for less than $2000 more than i was quoted, i now have a torquey beast which will last a long long time!  if anything, i would recommend at least going with total seal, and the fs-2500 filter.

the injector nozzles are the cheap ones though... so i will run them until they start smoking and possibly upgrade to bosio or just run the stock .205's.  (currently running the .216's)

this was more of a learning experience than anything.  i lucked out with the injection pump i bought from vdubfun (check earlier page for pics) as it was TDI ready, for cheap. getting the LDA and tuning wasn't too bad either.  mTDI pumps are still a bit of a black art, but mine seems to run just fine.  it's really interesting how it idles so quiet (no diesel clack) when its cold.  that could be attributed to lack of fuel pressure though... those bugs will have to be worked out.  i especially like having the cold start lever functionality with this pump (idle speed boost & timing advance).  i could probably start at -30C or even -40C (with synthetic oil) without issue.

i'm going to take a video shortly so stay tuned!
Title: m-TDI Swap! Into MK2 Jetta
Post by: snakemaster on December 26, 2008, 01:55:26 pm
some nice work you have done there ,looking forward to see the pics
Title: m-TDI Swap! Into MK2 Jetta
Post by: andy2 on December 26, 2008, 04:08:31 pm
I forgot to tell you that I checked the glowplugs and only cyl #3 glow plug lit up the test light.This might be the reason It chugged on startup.Those glow plugs are pricy but might be worth replacing :lol:.
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on December 26, 2008, 07:57:14 pm
Quote from: "andy2"
I forgot to tell you that I checked the glowplugs and only cyl #3 glow plug lit up the test light.This might be the reason It chugged on startup.Those glow plugs are pricy but might be worth replacing :lol:.


 :shock: wow... i'm amazed it starts so easily... i'll have to get the compression checked on this thing!  :lol: i can only imagine how it will run with the rings properly broken in  :D

i looked all over for the camera today but couldn't find it... i found it later but it was too dark to give a good video.. i'll try to take it tomorrow.

after approx 200km, the oil has a hint of black in it.  obviously the filter doesn't work too quick, but around 10-15 mins of driving *should* filter all the oil considering the flow.  this means that theres always going to be 15 minutes of soot buildup left in the oil, but we can't have everything  :wink:
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on December 28, 2008, 10:13:26 pm
so no real updates... weather was crappy so i didn't get the video done yet (should soon)

i'm wondering if anyone has advice on glow plugs.  i've heard that Beru are a really good name, better than the bosch duraterms. $26.95 vs $17.95 though...

thanks
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on January 02, 2009, 03:29:59 am
quick update:

i started the car without glow plugs @ -16C (weather network, actual temp unconfirmed)  :shock: with the car stumbling very briefly (very very briefly...)

after car sits for more than 8-10 hours though, it takes a few cranks to start up.  but after sitting just 2-3 hours, it will crank over just fine on the first revolution. and there is no way that residual heat will be assisting the cold starting after 3 hours, because there is none to speak of.  the car is as bone cold as after 8 hours, so it must be a fuel related issue.  i just hate starting the car with air bubbles...

so far this is looking to be an excellent build!  maybe i won't need to buy glow plugs after all  :lol:  Total seal FTW(ter)!  :lol:
Title: m-TDI Swap! Into MK2 Jetta
Post by: Ziptar on January 02, 2009, 01:21:03 pm
I just caught up with this thread.

That is awesome jtanguay! way to stick to it! Just what I needed to see as I've been feeling down lately, with the new job lest year, moving the family unit 1400 miles North and etc, the Jetta has barley seen a wrench and there is so much to do yet.

Speaking of which, when I drove the 03 Jetta up here last year it was still pretty cold. The idle was really chuggy and when it is cold. The GPs were shot, well, they were 5 years old and probably never came on in the 5 years the car was in Florida. DIs start really well in the cold without GPs, in fact I thing the Cummins B-Series engines don't even have them.

I got a set of Champions to get by on at NAPA for ~$11.00 each, you might want to grab a set of those just to get through winter.
Title: m-TDI Swap! Into MK2 Jetta
Post by: jtanguay on January 02, 2009, 01:36:19 pm
Quote from: "Ziptar"
I just caught up with this thread.

That is awesome jtanguay! way to stick to it! Just what I needed to see as I've been feeling down lately, with the new job lest year, moving the family unit 1400 miles North and etc, the Jetta has barley seen a wrench and there is so much to do yet.

Speaking of which, when I drove the 03 Jetta up here last year it was still pretty cold. The idle was really chuggy and when it is cold. The GPs were shot, well, they were 5 years old and probably never came on in the 5 years the car was in Florida. DIs start really well in the cold without GPs, in fact I thing the Cummins B-Series engines don't even have them.

I got a set of Champions to get by on at NAPA for ~$11.00 each, you might want to grab a set of those just to get through winter.


i might just do that thanks!  yea the cummins use intake air heaters...  one thing i've really been contemplating though, is hooking up the glow plug coolant heater system... this thing doesn't really make a lot of heat.  thats about the only thing i miss from my 1.6.  of course driving on the highway its fine though... but around town it'll never stay up to temp unless my heat is off... :roll:
Title: m-TDI Swap! Into MK2 Jetta
Post by: cyrus #1 on January 02, 2009, 04:05:57 pm
What sort of fuel economy are you seeing?  I can't help but think it should be pretty good with those total seal rings.  :twisted:
Title: m-TDI Swap! Into MK2 Jetta
Post by: Sierra94 on January 02, 2009, 05:16:56 pm
Sorry for borrowing your post but...

I did a M-tdi (AHU) conversion in my old Mazda truck this weekend. I had a 1.9 AAZ in it before. And I had to hook up the glow plug coolant heater system to get some heat out of it.

I hooked them up to a relay so that whenever the alternator is putting out power the glowplug heater is active. That way I donīt have to worry about overheating the system or draining the battery.

Mine starts without problems without blockheater or working glowplugs in -14 Celcius (checked it this morning). And the engine has 420000 km on it  :D I couldnīt beleive it myself.

I should have gone with a M-Tdi a loong time ago if I knew this earlier.
Title: m-TDI Swap! Into MK2 Jetta
Post by: rallydiesel on January 02, 2009, 06:17:15 pm
So when do the pics go up?!?!?! I want some inspiration for starting my project.