Author Topic: 97 TDI 1Z engine for 130whp, help please... (Read 8674 times)

quietmission · « **on:** December 24, 2007, 04:19:44 pm »

After a long search for an IDI td engine, i just scored a 97 TDI engine core instead, which will soon be rebuild. I have a T3 and a vnt15 but leaning torward the T3 for simplicity & more boost (22 to 25psi). I will get a PP downpipe to go along with the T3.
For the botton end (still sitting on a pallet with tranny attached in the back of my toyota pickup

), I will also do the total seal rings and according the experts here i will need to buy oem rings and send it in. Is that correct? I am also debating the pistons coating. I want to delete the EGR and i would like to know if i can still use the same intake manifold or should i buy the PP one. I think that i will go with .216 injector nozzles from JB Morrison or Smog on the TDI forum.

Basically, i am aiming for around 130whp which seems more realistic. So what else can i do while i will be at the rebuild process? Will these mods net to 130whp?
For pump, i plan to go mechanical (Giles Pump) and for that i think that i will go with the AZZ pump with a 10 or 11mm head and rotor. Please advise and it would be greatly appreciated!

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quietmission · « **Reply #1 on:** December 26, 2007, 10:33:08 pm »

Anyone?

Tintin · « **Reply #2 on:** December 26, 2007, 10:49:40 pm »

I can only answer you that yes, with a giles pump, 216 nozzle, T3 at 20-22psi with a proper intercooler you will have an easy 130-140HP.

I suggest you a 10mm M-pump, It's easy to run mechanically, reliable and give good power/economie.

jtanguay · « **Reply #3 on:** December 27, 2007, 01:40:19 am »

i'm pretty much doing the same build. I have the .216's installed by Giles, and a freshened up head (new lifters, guides, planed a bit..)

bottom end is all done with new bearings and total seals. my machine shop guy said the bores were near new spec which was cool. this coming from an engine over in Europe with around 120'000km. a product of good oils and cleaner fuel.

i'm also getting my pump done up by Giles with an 11mm head i'm getting from Smog. he said he got a few in stock so i gobbled it up :wink:

i believe that Giles could give me easily 160whp with this setup. all i really want is fuel economy and longevity, but the extra power would be nice!!! what I may end up doing is asking for more power at 15-18 psi and keeping stock boost levels, but using a manual boost controller to give power on demand :twisted:

i'm interested in seeing your project complete. the way things are going with mine i'll be waiting a while... :cry: basically need to get the vnt linkages setup and a new water pump, and clean up a few parts oh yea and the timing belt kit...

quietmission · « **Reply #4 on:** December 27, 2007, 09:10:53 am »

That should be good enough if i can get 130hp :lol: but more is always better. Where did you get your rings from and how much? Do you have a reference at Totalseal that i can go through since they already did yours.
What are you doing for your intake manifold to delete the EGR? I like Dave's manifold but trying to weigh my option.

quietmission · « **Reply #5 on:** December 28, 2007, 01:52:31 pm »

1Z block is now at Chris Hill at Kraftwerks

. Thanks to fellow forum member Justin aka "Greasecar" for connecting me with Chris.
Chris has a great collection of diesel especially TDI's :shock: . He is very knowledgeable and is well known in the area. I will post update as they become available.
Please feel free to offer suggestion.

ninedee_golf_tdi · « **Reply #6 on:** December 30, 2007, 06:34:54 pm »

Total Seal Rings. You only use one of them per piston, normally the second ring. The top and oil rings are vw oem or equivalent, thus the reason to have to buy both. The skirts of the pistons already have an anti-friction coating on them. I generally have the top of the pistons coated with ceramic to reflect heat.

MikkiJayne · « **Reply #7 on:** December 30, 2007, 07:43:33 pm »

The Total Seal reference is S9205. This is a full set, not just the second ring. It has standard 1st and oil rings, and gapless 2nd.

Go on to http://www.totalseal.com and search by application. You wil find the set for the 1900cc diesels easily. They also list dealers on the web site too.

I know people have sent OE Goetze rings to be modified, but my Total Seal dealer builds race engines for a living (competitive ones!) and swears by them, so I have no reason to doubt him.

Mikki x

jtanguay · « **Reply #8 on:** December 31, 2007, 07:23:04 pm »

hillfolk'r was told by total seal rings that they couldn't make better rings than OEM Goetz rings. I just bought them from myke_w and he sent them to total seal, and then total seal sent them back to me. pretty pricey but it'll be worth it.

i'm definitely deleting egr. since i'm using a 1.6TD exhaust mani, i don't need to worry about blocking the port off, and i might be using an intake off of a PD130.

i'm also seriously considering an air/water intercooler setup. i believe they are far superior, but more complex and obviously more $$$

ninedee_golf_tdi · « **Reply #9 on:** December 31, 2007, 07:47:33 pm »

I could have sworn I read you were installing gapless rings in this engine, thus my comment about you only using one of them per piston. Here is a pretty good description of building an engine with them.

"There are other piston rings on the market that offer an engineering solution to the problem of a large ring gap. The gap is "eliminated" by using two thin rings that fit in one groove, staggering the ring gaps. These "gapless" rings are available in a Top or 2nd ring version. Aircooled.Net recommends the Total Seal gapless 2nd ring for street use, and the Total Seal gapless Top ring for racecars. Never ever use gapless rings in BOTH the Top and 2nd position in the same engine! The Total Seal gapless ring design definitely helps in ring sealing, but don't expect it to eliminate all the other cylinder preparatory work! If you're just replacing your rings (and not buying a piston set which includes rings) the best quality replacement piston rings are Deves brand. They are really easy to install and break in quickly, without headaches."

Stolen from here: http://www.aircooled.net/gnrlsite/resource/articles/pcrops.htm

MikkiJayne · « **Reply #10 on:** January 01, 2008, 09:47:03 am »

Yeah the OP said he is using Total Seal in the first post

If you're in America then it makes sense to send Goetze rings to be modified, since then you know you have the best possible setup. Alas I'm in the UK so its just not feasible to do that, hence why I will buy the set of TS's own rings.

quietmission · « **Reply #11 on:** January 13, 2008, 06:02:11 pm »

Just scored a complete ALH core with pump etc...$100. I got it from this guy that replace an engine for a customer. Apparently the customer drove the car to the shop that i got it from (barely made it in). I was told low oil pressure and the PO was running veggie oil or something. For $100, i don't really care much. Could it that bad? What should i do first to it?

RabbitGTDguy · « **Reply #12 on:** January 13, 2008, 06:37:14 pm »

Wow...I'd say thats not a bad deal any way that you can look at it... you've got WAY more than that in parts and probably a perfectly rebuildable core.
Low oil pressure could be any number of things...I think I would start with a compression test ...look at rings, etc.
For that price though...its well worth the teardown and build up. Wish I could find an ALH core for that price!!! I seem to only have luck finding the older 1z/AHU motors..

I think I'd almost use the ALH motor since its there and fairly complete as well. A bit of a stronger base to work with as well without having to mix and match parts. If you end up parting the other one, I have a few things I'd be interested in! Namely a set of injector lines if you have them (for 1z/AHU) but man....what a deal!

Joe

quietmission · « **Reply #13 on:** January 13, 2008, 07:17:11 pm »

True indeed! I can't believe my luck... I have waiting the longest to get an older 1.6td but now it seems that i am TDI all the way.

Definitely, i want to do a full tear down on it and build it for maybe a mk2 gti or an mK3 golf VR6 or GTI shell. The other engine will probably get thrown into a suzuki sidekick 4dr or something.

I will let you guys know what i decide. And keep it coming with the advice...

thanks!

quietmission · « **Reply #14 on:** March 12, 2008, 10:59:18 pm »

Recently acquired a VNT20 turbo that i will run mechanically with Tintin's help. I am also going with a 10mm MTDI pump that i am getting from another member here. I want it to go into a 2nd generation 4runner.
How much power can my little 1z make now

?