Well I worked a lot for racing companies, building up the engines. This combined with my love for diesel engines resulted in a small company for diesel modifications. I get a lot of people with a MK1 Golf, Jetta or Caddy that want a TDI engine in there car. Most of them don't want the electronics. (and I don't like electronics
)
A German friend of mine and ex-boss has been racing and sprinting for a long time and he wanted to make a killer diesel sprinter, money no issue. That's were I came in.
We discussed what the goal should be. (something around 250ph/500Nm) I told him that he would get problems on how to get the power to the road with the MK1 Golf. His thought: Lets adapt a 4-motion or Quattro driveline.
So it started about a year ago. He bougth the Golf and starting to strip it. Bought an Audi A3 1.8 20vt quattro with six speed gearbox as a donor car.
The whole driveline was send to Drenth transmissions to convert the gearbox to straigt gears, quaife differentials and some other stuf so the electronics could be removed. The Clutch is a Tilton multiplated one at the moment, but due to the fact that there is a lot of torque at very low rpm's we need to find something different.
All the engine parts are new or special fabricated. I bought a new engineblock (AFN) and head at Vege motors.
Took out all the internals putted the original Pistons on the 3D measuring table. And created a 3D point cloud. After that I created in Catia V5 the pistons the way I wanted them. There is oil cooling in de head, slightly different combustion chamber, The crooves were changed to adapt race rings and I changed the diameter to get a 2 liter engine. (Could go higher, but I don't think it's wise for the strength of the engineblock)
I took out a little bit more material to create more space for the valves. 28mm pistonpin.
Called up a couple of companies that are able to make this custom set of pistons and finaly JE (America) made them including slide coating on the side and thermal coating on the top.
Next step was getting a set of Rods. When I called JE how it was coming allong with the pistons. I asked him for a recommendation on Rods and since JE and Carrillo are cooperating the choice was easily made. He introduced me there and after 4 weeks I had my custom rods with oil feeding for the piston cooling.
Than I took the engineblock to a friend which is building up race engines almost all his life.
He was going to buildup the engine block to full race specs. I asked him to take of as little as possible from the crank, only that what is nessesary for balancing. He also changed the oil supply to drysump. After a couple of weeks it was ready.
Compliment from him to JE-Pistons. (The pistons are of high quality and pefectly balanced.)
Meanwhile I started on the cylinderhead. Started taking out the swirl from the intake (don't know the english name) Changed the valve seats to ones with a different angle. Took out some material to get clearance for future higer lift cam.
Then had contact with Kent cams if they could change a cam for us. Finaly it resulted in a new cam. The couldn't garantee the strength of the original modificated cam. Kent supplied also stronger valve springs
Fratelli Bosio supplied the nozzles and our local Bosch friend changed the injector bodies. (original Transporter T4 2.5TDI 220/300Bar)
We tried a Cummins fuelpump-body, but finaly we chose a modificated 1900TD (AAZ) one. Now it has got a 14mm plunger with standard camplate from an AHU TDI. The original plunger springs I changed to ones that are 120% of the orignal strength (don't want a flying camplate on the followers) The pump cover came from a Renault master pump with changed Govenor and Custom LDA pin.
For a turbo we bought a nice new VNT-25 and had the baerings changed. A friend of mine welded the exhaust manifolt. With a pre turbo EGT probe installed. Anc an flange for the wastegate.
The intake is a custom longrunner intake from aluminium. Studs on the front of the cylinderhead to support it.
As told last week they went to a place where they can dyno 4wd cars. The result was very good! For the third run they had 278hp/593Nm at the wheels.
I told my friend that I couldn't garanty him that this engine would last long..... Don't know what the original parts can handle.
As soon as I get to them I'll take some overall pictures of the car and dyno plot. (we live 200km's from eachother)
Topic: vnt25 on a Tdi-m (Read 12994 times)
