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Author Topic: m-TDI Swap! Into MK2 Jetta  (Read 16397 times)
jtanguay
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« on: April 04, 2007, 04:05:48 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!!!  Cool

I will post pictures when i can!!!

edit: i've also noticed that this motor has the coolant glow plugs...  Cool
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jtanguay
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« Reply #1 on: April 04, 2007, 06:10:53 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...
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jtanguay
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« Reply #2 on: April 05, 2007, 03:17:26 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.
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wolfsburgnut
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« Reply #3 on: April 10, 2007, 01:08:59 PM »

Paint Gun Wash,  that stuff will strip anything!

Peter
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jtanguay
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« Reply #4 on: April 10, 2007, 03:18:04 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!
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935racer
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« Reply #5 on: April 12, 2007, 04:35:14 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 Cool


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jtanguay
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« Reply #6 on: April 12, 2007, 05:19:38 PM »

wow! that thing is beautiful!  yep no EGR!
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« Reply #7 on: April 26, 2007, 04:38:42 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.
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jtanguay
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« Reply #8 on: April 26, 2007, 05:03:17 PM »

thanks for the info!  the pump i have i bought from vdubfun.



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!)
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scopefrfd
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« Reply #9 on: April 26, 2007, 05:09:32 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.
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jtanguay
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« Reply #10 on: May 10, 2007, 12:03:10 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:
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scopefrfd
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« Reply #11 on: May 13, 2007, 08:39:04 AM »

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.
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jtanguay
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« Reply #12 on: May 13, 2007, 07:45:49 PM »

what is the best way to contact them??? i e-mailed last week... i guess phone now?  :?
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jtanguay
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« Reply #13 on: May 14, 2007, 02:36:40 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.
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« Reply #14 on: May 27, 2007, 07:06:46 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:
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MKII Jetta Carat Turbo Diesel 220,000 miles
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