vr to td?

[FusLit]

Since I got shot down via the wife on a turbo diesel passat, I'm seriously thinking about putting the turbo diesel motor that I have into my jetta.

The motor it's self It will not be stock but will it have enough power to push the car (and bike rack) at an acceptable speed?

Non standard things that I have and most likely will be on it
- Raceware head studs
- GTD injector nozzles
- Bigger turbo
- Large Intercooler (was in Ryan's rabbit)
- 16v passat o2a trans with a tdi 5th gear
- rebuilt turbo diesel pump with some mods to push rpms, and more fuel.

Things I'd like to put on it/keep.
- Serp belt kit from 2.0
- metal head gasket
- abs

future?
- 1.9 turbo diesel head
- frybred wvo tank?
- bio-diesel

Things I know I need:
- Tdi fifth
- flywheel (will a tdi flywheel bolt up I've got one?)
- starter
- serp belt conversion & alt (unless I can use the vr's)
- Downpipe and Exhaust

What else do I need to change / swap to get this to work?

Also, since I have no urge to keep it, I'd be looking to sell my vr swap (which just had timing chains done, new clutch, etc etc) motor, trans, engine harness, whatever else I don't need but would be useful to have.

Thoughts?

-Todd

[car_whore]

Just because of your signature:wink:

01001001001000000111011101100001011011100111010000 10000001110100011010000110010100100000011101100111 00100010000001100110011011110111001000100000011101 00011010000110010100100000011000110110000101100100 01100100011110010010000001100010011101010111010000 10000001101000011000010111011001100101001000000110 11100110111100100000011011010110111101101110011010 010110010101110011001000000011101000101000

[VWTUNING]

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[vwremglx]

%42%69%6e%61%72%79%20%69%73%20%66%6f%72%20%6c%6f%6 f%73%65%72%73%2e%20%68%61%21%21

[VWTUNING]

HA!


he said 69 :laugh:

[B4passatglx]

go tdi

VR6's are finicky pieces of engineering

[FusLit]

%42%69%6e%61%72%79%20%69%73%20%66%6f%72%20%6c%6f%6 f%73%65%72%73%2e%20%68%61%21%21

59:6f:75:72:20:61:20:6c:6f:73:65:72:20:77:2f:74:68 :69:73:20:67:61:79:20:68:65:78:20:73:68:69:74

01100001011011100110010000100000011000100110100101 10111001100001011100100111100100100000011010010111 00110010000001100110011101010110111000100000011000 01011011100110010000100000011000010110110001101100 00100000011000100111010101110100001000000111010001 10100001101001011100110010000001100100011011110110 01010111001100100000011011100110111101110100011010 00011010010110111001100111001000000111010001101111 00100000011001100111010101110010011101000110100001 10010101110010001000000110110101111001001000000111 00000111001001101111011010100110010101100011011101 000010000000100000001000000011101000101000

-Todd

[tube bias 25]

neo is that you
00010000010000010000001000000100000010000100000000 00000010001
00000000000010000000000000000010000000000010000000 00000010001
10000000000000100000000000000001000000000000000100 0000000101
00001000010000000000000010000000000000100000000010 000010000000
00100000000100000000010000000000100000000010000000 00000100001
11011111110000000010000111011010111010100000000000 10001110001
11100000000111111100000000011100000000000111000000 0000110

[tube bias 25]

http://i238.photobucket.com/albums/ff231/verve25/pacman-killer.jpg

[FusLit]

go tdi

VR6's are finicky pieces of engineering

Turbo diesel is what I'm going to go with originally because it's what I have on hand for the moment.

I'm working on getting a tdi engine swap but it needs to be rebuilt and a few other things before I can get there.

-Todd

[evolveVW]

TD still can make plenty of power modded, all the Mk3 canadian Golf diesels were TDs (granted 1.9s) but a modded 1.6 should be good. May not even need to go TDI. Also- I'll sell my WVO setup fairly cheap :smile:

[FusLit]

TD still can make plenty of power modded, all the Mk3 canadian Golf diesels were TDs (granted 1.9s) but a modded 1.6 should be good. May not even need to go TDI. Also- I'll sell my WVO setup fairly cheap :smile:

I'll keep it in mind Vin, at the moment todd = no money *grin*

I think I'm close with what I need project wise, just trying to find some more info.

Sadly I've not been exactly successful finding anything that talks about swapping a vr for a 4 banger...

-Todd

[KPz]

u getting rid of the VR thats coming out of the car to fund the swap? or you gonna keep it for another project?

[evolveVW]

Well, since you are using an 02A just use the VR axles etc. Probably going to need to replace the fuel lines and replace/ or clean the gas tank. Retain the driver's side harness that goes to the starter, alternator, and speed sensor (Just keep the one you have, it should work) You then need to figure out what on the TD needs power/wiring and go from there. Most of the VR harness will be useless.

[VWTUNING]

One issue will be the harness... since MK3's are all integrated, its going to be tough to seperate the cooling and lighting. Might want to look into getting MK2 Jetta stuff (90+ CE2) cause they have seperate harness's for lighting, cooling, and engine management. From what I remember 95% of the connectors were the same between MK2 and MK3 (head lights blinkers etc....)

[BUNNYLOVE]

IDK, you could just uplug the engine connectors and leave them alone. Hook up your GP and fuel cutoff on their own and call it a day. You don't even have to think. This is a TD so there is very little wiring.

OR you could get the harnesses from a TD Jetta in Canadia. I know Joe did this for his B3.

[evolveVW]

One issue will be the harness... since MK3's are all integrated, its going to be tough to seperate the cooling and lighting. Might want to look into getting MK2 Jetta stuff (90+ CE2) cause they have seperate harness's for lighting, cooling, and engine management. From what I remember 95% of the connectors were the same between MK2 and MK3 (head lights blinkers etc....)

I was able to separate the cooling, light, and starting circuits without very much trouble when I swapped.

[VWTUNING]

I did too at first, but it was a huge PITA (IMO) and I wouldnt recomend it :laugh:


Im sure mine being OBDII didnt help though.

[FusLit]

u getting rid of the VR thats coming out of the car to fund the swap? or you gonna keep it for another project?

- It's not funding the project so to speak, but I will be selling it.

Well, since you are using an 02A just use the VR axles etc. Probably going to need to replace the fuel lines and replace/ or clean the gas tank. Retain the driver's side harness that goes to the starter, alternator, and speed sensor (Just keep the one you have, it should work) You then need to figure out what on the TD needs power/wiring and go from there. Most of the VR harness will be useless.


- I planned on using the vr6 axles
- Haven't had a chance to think about fuel lines yet. if they're crappy looking I'll re-run them.

Yeah, I was pretty sure the vr harness is pretty useless. I wasn't sure how much I would be able to use, I've got a couple mk2 harness's I got off of Karl, I'll have to check if they're. That's a good idea RyanI'll see if I can trackdown a mk3 td harness from Canada (or at least see what they're selling for.)

Worse comes to worse I pull it apart and re-wrap it.

-Todd

[BUNNYLOVE]

Something else to consider is that selling the VR with a good harness might get you some more money for it.

[FusLit]

Something else to consider is that selling the VR with a good harness might get you some more money for it.

True, at this point I'm not sure what the engine/trans would be worth.

Would I be able to use the clusters temp/trip/averagespeed/etc any more or will it be gone (I'm assuming it won't work.

I'll have to do some research on the sensor's that are there, it'd be neat to try and keep as much working as I can.

Will an o2j fifth gear work in an o2a? (Sorry if I asked that already)

-Todd

[BUNNYLOVE]

I'm not sure how the speedo and stuff works on a MK3 but I'm guessing its through the ecu. So you might want to source a cluster too.

You can use a O2J 5th in your O2A I believe you just have to make sure the fifth gear syncros parts are matching your gear set.

[rabbitgtdguy]

Todd,

We talked about this briefly last night...but all of the ideas sound good for the most part.

Your easiest options honestly would be to pull the entire VR harness and get a mk3 AAZ harness out of CAN from a parted AAZ car and run that. However, you might find that a CE2 (late) MK2 diesel harness would be fairly plug and play as well...especially since your running a non electronic diesel, etc. (starting with the IDI TD and later going to go with a mTDI I believe). I have a b3 AAZ downpipe that would be good to use for mock up/fabbing purposes to get the correct orientation in there for the downpipe.

As for speedo. The mk3 clocks on the VR are electronic of course, driven by a VSS signal. However, the nice thing about the 02a's is that the VSS just unscrews from the tranny if you had to go that route. I'd have to correct myself if I'm wrong... mk3 AAZ's had a manual speedo cluster (very similar to the early b3 AAZ cars...I have one for the b3 here) and that could be sourced out of CAN as well. If not, You could use a few items from a mk3 TDI cluster and you'd have to run the VSS harness (to make the speedo work) and would ahve to find something to drive the tach (driven by ECM on TDI cluster). Again...easiest is sourcing AAZ MK3 specific parts from a CAN car....up for sale quite a bit!

It'd be nice as you'd already be primed for a TDI swap later on...nice that you'd already have 5 lug...beefier wheel bearings...and all the other bits that you already have on the car. The diesel wiring harness itself is simple and should be easy to adapt either way (whether you use a AAZ harness...or something from a later mk2 diesel (which you have a couple I think)).

I like the sounds of this project...and you'll net quite a bit back with the sale of the VR and its trans.

Starting IDI TD...I think that 16v tranny and its slightly lower geared final (3.67) for AYK (if thats what one of yours is) would be more optimal since your not starting off with all the low end torque that a TDI would provide and the fact that the little 1.6TD is going in a heavier car. The lower final drive at 3.67 would be nice for this motor I think and if you ran a TDI 5th....that'd be even better (as I feel the 16v itself could benefit from the TDI 5th cruising on the highway sometimes!). It will rev slightly higher...but in reality, the older IDI TD's revved higher on the highway in the first place to keep them in the powerband for hill climbing power, etc. Most earlier diesel trans ran a 3.89 final or closely similar. Many look for the 3.67 in the 020's even now for their IDI's. I can tell you having a 3.89 final in the current mk1 mTDI's trans is a scary thing at the very least...and it def. could rip the tranny to shreds if I pounded on it...but you can see once you drive a TDI vs. a IDI TD "WHY" the trans were geared this way.
The only downfall here is if somehow...for some reason someone at an inspection depot would want to check the engine code on the motor and find it came from an "earlier" car...which is technically illegal (since all specs have the meet the specs for that paritcular model....that "production" year). Though...i doubt anyone would know the difference.

[FusLit]

Thanks for confirming the gears Ryan and for weighing in Joe.

I'm putting together a list to start figuring out what I have and what I need to get finished up. we'll go from there I guess

-Todd

[FusLit]

So, the list I have so far.

I have an engine (supposedly freshly rebuilt) with the following crap in it. http://fuslit.org/turbo-diesel.html

Will be re-refreshed with the following:
- degrease/clean engine
- swap out oil pan for the correct one
- replace turbo return line
- injectors with ones rebuilt with GTD nozzles
- Clean and install bigger turbo.
- new timing belt
- will rebuild TD Injection pump and replace current Audi one (maybe)

Needed:
- g60/tdi flywheel [Resurface]
- vr6 clutch kit
- TDI fifth gear set

(now have lead on)
- AAZ serp belt swap
- AAZ mk3 harness
- diesel starter which will fit an o2a

I'm still on the fence about the harness. I might modify the current harness... depends what the cost of the other stuff might be. Anyway, I'll start taking some pics of where the engine is currently and continue to document as I get closer :)

Also started thinking about the intercooler and exhaust piping, I want something which will stand up to NYS winter salt as this will be a Daily. SO I'm thinking invest in stainless piping all around. Pull my current exhaust, I'll need to build a DP anyway.

-Todd

[iceVee]

I think you should go straight to a TDI, and skip the 1.6 TD.

Why plan on two swaps when you could just do one, save yourself time and money in the long run, and not have to worry about the early-engine-in-later-car legality issue.

Since you won't be using the 1.6 TD, you'd want to sell it to someone with a Mk2 Jetta NA 1.6 diesel who would be willing to take the 1.6 off your hands so you could skip all the intermediate work and save yourself all the time and hassle of two engine swaps instead of one.

If you want, I can check around and see if there are any Mk2 Jetta NA 1.6 diesel owners around here who need a turbo upgrade...

Subtle, eh?

[BUNNYLOVE]

LOL, real subtle. :laugh:

[FusLit]

I think you should go straight to a TDI, and skip the 1.6 TD.

Why plan on two swaps when you could just do one, save yourself time and money in the long run, and not have to worry about the early-engine-in-later-car legality issue.

Since you won't be using the 1.6 TD, you'd want to sell it to someone with a Mk2 Jetta NA 1.6 diesel who would be willing to take the 1.6 off your hands so you could skip all the intermediate work and save yourself all the time and hassle of two engine swaps instead of one.

If you want, I can check around and see if there are any Mk2 Jetta NA 1.6 diesel owners around here who need a turbo upgrade...

Subtle, eh?

*grin* well I don't think I'd be able to sell the current engine I have, get a tdi replacement and still be able to afford to do the swap.

(if that makes sense)

But, I do happen to have a couple few diesel motors (2 more td's in various states of disrepair. i.e. most likely will be missing parts) Although, I might be able to be convinced to sell you a couple longblock projects of your very own.. They would be a build one out of two and def need to visit a machine shop, most likely need to find a decent head... I have IP's but have to decide what I'm gonna do w/the current projects I have before I sell..

Hey, for what it's worth, I even have one torn apart and cleaned a bit for you... :icon_wink:

what's your budget *grin*

-Todd

[iceVee]

*grin* well I don't think I'd be able to sell the current engine I have, get a tdi replacement and still be able to afford to do the swap.

(if that makes sense)

But, I do happen to have a couple few diesel motors (2 more td's in various states of disrepair. i.e. most likely will be missing parts) Although, I might be able to be convinced to sell you a couple longblock projects of your very own.. They would be a build one out of two and def need to visit a machine shop, most likely need to find a decent head... I have IP's but have to decide what I'm gonna do w/the current projects I have before I sell..

Hey, for what it's worth, I even have one torn apart and cleaned a bit for you... :icon_wink:

what's your budget *grin*

-Todd

Budget? Got no stinkin' budget! :laugh:

I don't need a turbo - just trying to help a brother out!:smile:

Besides, I have plenty of projects myself which have been languishing in something dangerously similar to Todd-time. In reality (theoretical, I know, but they tell me it exists) I'm not planning to do anything to my diesel unless the motor self-destructs. So, I'll have to live vicariously through the TD upgrades of others.

[FusLit]

Budget? Got no stinkin' budget! :laugh:

I don't need a turbo - just trying to help a brother out!:smile:

Besides, I have plenty of projects myself which have been languishing in something dangerously similar to Todd-time. In reality (theoretical, I know, but they tell me it exists) I'm not planning to do anything to my diesel unless the motor self-destructs. So, I'll have to live vicariously through the TD upgrades of others.

Well, I'm serious about putting up some diesel crap for sale, so if you need anything let me know.

-Todd

[FusLit]

Yesterday I started getting the motor torn down so I can clean it up a bit before I swap and make sure things are in order.

http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20080713_turbo_diesel/IMG_0956_640.JPG

Head looks 'clean'

http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20080713_turbo_diesel/IMG_0964_640.JPG

I've got a 'real' td oil pan, so I've pulled the one that was on it (anyone want to turbo their car? I've got a spare oil pan... make me an offer)

http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20080713_turbo_diesel/IMG_0957_640.JPG

I've also pulled the clutch that was on it as it's for an 020 tran (a sachs something er other, I'll have to lookup what it is again. That might be for sale as well.)

http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20080713_turbo_diesel/IMG_0961_640.JPG

I found the code on my transmission it is is an AGC so I looked up the info on that.
_________1st___2nd___3rd___4th___5th___R&P____Notes
AGC====3.778 =2.105=1.345=0.971=0.795=3.944= Passat 16V

I've found a few sources for a tdi .775 fifth gear set. I'm wondering how much of a difference that it would make in the rpm's in fifth gear. I guess it'll depend what my final price point on the gears is.

For kicks and grins I test fit the serp/alt belt holder from the tdi I have on the motor, 3 out of four bolts fit.

http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20080713_turbo_diesel/IMG_0968_640.JPG

I'm debating on buying the serp belt from a 1.9 td now, but I think I will anyway as I'll need to pick up something for the tdi... although I've been thinking about just selling off the parts from the tdi I have that are good... (head, pistons, crank, etc...)

-Todd

[BUNNYLOVE]

Todd, 1.9 TDs and early TDIs use the same bracket as far as I know. It should bolt right up there, you probably just need the waterpump studs.
Its just like swapping an 2.0 ABA setup on to an older 1.8 gas engine.

[iceVee]

I found the code on my transmission it is is an AGC so I looked up the info on that.
_________1st___2nd___3rd___4th___5th___R&P____Notes
AGC====3.778 =2.105=1.345=0.971=0.795=3.944= Passat 16V

I've found a few sources for a tdi .775 fifth gear set. I'm wondering how much of a difference that it would make in the rpm's in fifth gear. I guess it'll depend what my final price point on the gears is.

-Todd

According to my math it would make about a 2.5% difference (2000 rpm would become 1950 at the same road speed, and 3000 would become 2925).

Not a big difference for the cost and hassle. Still might be worth it, depending on whether the rpm drop happens to hit in a crucial spot speedwise where mileage will jump up with a small rpm drop.

[FusLit]

Todd, 1.9 TDs and early TDIs use the same bracket as far as I know. It should bolt right up there, you probably just need the waterpump studs.
Its just like swapping an 2.0 ABA setup on to an older 1.8 gas engine.

I've got the studs, and it's bolted up. 3 out of 4 studs hit I've got the TDI Injection pump bracket (which has another point the serp bracket attaches to) and might try it out just to see if it'll fit. I'm pretty sure I can fabricate a bracket for the fourth stud w/out any problem.

http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20080713_turbo_diesel/IMG_0970_640.JPG

http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20080713_turbo_diesel/IMG_0969_640.JPG

This is good news for me as it'll save me some time (and money) if I use it. I've been leaning towards it and I guess i'll go ahead and part out my TDI. It should save me a bit of cash buying some parts, and time on attempting to rebuild the tdi... When the time comes for another project I want to go with a known running engine (less bugs to work out)

I believe I'll need a new alt, feel free to tell me which one to keep an eye out for, I know Joe's told me before but I don't remember what it is off the top of my head (Vr6?)

I've got all the pulleys that I can pull from the tdi as well for the serp stuff (and water pump if need be, but the one that's on the tdi and the 1.6 are similar.)


According to my math it would make about a 2.5% difference (2000 rpm would become 1950 at the same road speed, and 3000 would become 2925).

Not a big difference for the cost and hassle. Still might be worth it, depending on whether the rpm drop happens to hit in a crucial spot speedwise where mileage will jump up with a small rpm drop.


That's what I'm thinking, the rpm difference is fairly negligible. I'll have to think about it for a bit, I've got a lead on one for 80 bucks with no chips, that might be a decent one to pickup just in case.

one other non-related note. my impact gun is my new favorite tool!

-Todd

[BUNNYLOVE]

You'll want a TDI alternator most likely for the W terminal. I see what you mean now on that bolt. I'm sure it'll be fine with 3 bolts.

[lotar_6]

todd... buy that 5th... if you don't want it, I DO!!!!



srsly...

[FusLit]

todd... buy that 5th... if you don't want it, I DO!!!!



srsly...

I thought you bought one no less then 1 year ago (I didn't want to say anything but I did dig up your 'want to buy thread')

sent you a pm

-Todd

[allstarrme]

I'll buy that 5th if kyle doesn't. there is a 16v passat that just arrive in the binghamton yard with an AGC tranny and parts, if you need any spares.

[FusLit]

Sent people (on fastdubs) pm's on the tdi fifth gear sets that i'm inquiring about. I think I'm going to order one for myself (just in case the rpm's are super high) but more than one person contacted me about them so let me know.

I made some progress tonight.

pulled some more from the TDI (serp pulleys, vbelt pulleys for the h20 pump, ip bracket, lower belt guard, etc.)

So far, everything seems to swap over, the IP bracket while it does hold the pump, has some complications (the mounting points are off,) With only one bolt lines up and the 'outside' bolt which the serp tensioner belt is on does not line up w/the way it currently sits. Still for fun I put it on to get some ideas. Put the oil pan (held on w/three bolts) to see how it fits/sits and found a return line to test fit.

http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20080714_turbo_diesel_mockup/IMG_0973_640.JPG

the pulleys seem to line up (even though I suck at taking pictures to illustrate that point.

http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20080714_turbo_diesel_mockup/IMG_0975_640.JPG

with the timing belt on, the lower guard did not fit in place, but I was more interested in the TDI injection pump bracket then the guard so I test fit things w/out it.
http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20080714_turbo_diesel_mockup/IMG_0982_640.JPG

And my camera ran out of battery's, since I have other crap (non-car related) I need to get done so I quit for the night.

So, That's pretty much it for the night, not to shabby.

Thanks for the lead on the Passat transmission, I hopefully will not need spares just yet.

I am trying to uncover things in my pile of crap that I want to use on the engine (correct oil lines, etc) more progress tomorrow!

-Todd

[FusLit]

I took it part again, tore it down and separated the head from the block so I could make sure the head and pistons were ok.

http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20080716_turbo_diesel_teardown/IMG_0987_640.JPG

you can tell where at some point the valves were on the pistons (perhaps when I took the belt off?) while there is marks in the carbon, there really is no 'indent' so to speak.

http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20080716_turbo_diesel_teardown/IMG_0988_640.JPG

I feel better about moving forward with the rest of it, not that I was worried but it would be kinda sucky to get everything together to find that a piston is/was hosed. Everything appears to be good to go.

Found a different oil filter holder which has a turbo oil line part.

Can you re-use head gaskets? The # on the one that's in it is 285 049

I pulled the info off the turbo I might use (a k24 I think?)

anyway the tab is three lines... German

K *scratch so I can't read* NR: 069145703
ALT NR: 829180331
AUSFÜHRUNG: 5324 970 6081

Now I'm satisfied with the head and block, I'll start cleaning things up to get things ready for the 'build up' There are a couple seals that have small tears in them that I want to replace since I've got it down this far. I pulled the tdi flywheel from the tdi block and it should bolt up with out any problems! I'll call up the machine shop I use and have it resurfaced and start cleaning the transmission up.

I'm starting to compile a list of seals and bits I need for the build of the injection pump, block and transmission.

-Todd

[BUNNYLOVE]

Todd, it looks awesome. I wouldn't re-use the head gasket. You can get away with it with mls type gaskets but not fiber gaskets and def. not on a diesel.

[FusLit]

Thanks, the plan is to use a AAZ 1.9 metal head gasket in place of what's there. I thought re-using was out of the question, but I wasn't 100% sure. Shame I can't re-use because the P.O said it only has 100 miles or so on it. Ah well, I'd rather have checked and make sure of the condition of stuff. The head does appear to be pretty decent.

I've found a source for a mk3 engine harness up until the twist/click connector so I'll probably pick that up, and a diesel starter as well. I might be catching up with him this weekend to get those.

We shall see.

-Todd

[FusLit]

ordered a tdi fifth gearset (thanks Fletch63 on the tdi club)

hopefully it'll work as expected.

Life's been a bit hectic on my side as of late so no new progress tearing the engine down, but I might have a lead on the parts I'll need to button it back up (headgasket, timing belt, tensioner, etc.)

-Todd

[kabinotar]

Good news Todd!

http://rochester.craigslist.org/pts/763790917.html

[FusLit]

Good news Todd!

http://rochester.craigslist.org/pts/763790917.html

looks like the same dude I spoke w/monday who agreed that I'd be able to check it out but hasn't called me back. I notice his price has also gone up 100 bucks...

original thread:
http://www.fastdubs.org/forums/showthread.php?t=15932

when I spoke w/him on the phone @ 8:30 mon night I think he was completely hammered/high so I doubt he even remembers me calling him... I could be wrong. Anyway, he didn't remember talking to me 4 hrs earlier in the day until I walked him through the whole damn conversation I had with him. Then he says with a bit of a slurred voice
I'll call you wed and give you the address, I don't want to give it to you over the phone right now

I was like eh, maybe I woke him up and he's delt w/alot of shady character's on CL so I'll play along *shrug* anyway, I haven't heard from him... But the day is still young, maybe he'll call and I might still check it out. but ... idk, kinda weirded out by that whole phone call honestly...

I'll keep you posted.

[FusLit]

http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20080723_motor/IMG_1005_640.JPG

Gonna try and paint the block this weekend :)

-Todd

[meatwad!!]

wow. awesome.

you should put that in another car besides your vr.... ya know..you do so then there was really no point in me telling you that.

this is the frist time i have seen the thread, i checked most of it out(the pics and some chatting) i skimmed.
nice progress! get it done!


i want a diesel

[FusLit]

wow. awesome.

you should put that in another car besides your vr.... ya know..you do so then there was really no point in me telling you that.

this is the frist time i have seen the thread, i checked most of it out(the pics and some chatting) i skimmed.
nice progress! get it done!


i want a diesel

Thanks, The whole project is a bit of an experiment :)

Well, the thought of finding a different shell has crossed my mind multiple times, we'll see at the moment I'm a cheap bastard mk2 stuff is getting harder to find at a decent price that's not rusted worse than my mk3. so unless a rust free shell falls in my lap (not likely) I'll be using the vr for the swap... I've got a set of snows for it, its one less thing I need to coordinate and as the saying goes such is life.

-Todd

[meatwad!!]

ill keep and eye out :wink:

[FusLit]

I made some progress getting the block painted, some seals replaced and need to order some parts to put it back together. Point is, I'm starting to make some more progress on it!


http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20080918_shortblock/IMG_1287_640.JPG

http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20080918_shortblock/IMG_1288_640.JPG

-Todd

[VRsuper6]

fire it up!


page 6!

[lotar_6]

fire it up!


page 6!

page 2... change your settings! lol

[FusLit]

fire it up!


page 6!

hah, you are new around here. Read a few of my threads to get an idea of how damn long it takes me to get something done x-)

next up on the list is finish cleaning up the parts for the block, get the head gasket and get the motor wrapped up. In between working on some other things.

-Todd

[kabinotar]

Nice Todd. :smile:

[iceVee]

I still think you should sell this to me and put the TDI in your car :laugh:

Nice progress, I'm impressed.

-K

[FusLit]

ordered this today
- timing belt
- tensioner
- 1.9 aaz 2 notch metal head gasket
- exhaust gaskets for the head

-T

[VRsuper6]

sweeet. have you had your flywheel resurfaced yet? i think you should do it yourself :wink: you should learn how, lol. i have a spare VR flywheel you can use to practice on...

[BUNNYLOVE]

Awesome! Did you figure out what your going to do with the fuel tank and stuff yet?

[FusLit]

Awesome! Did you figure out what your going to do with the fuel tank and stuff yet?

I have not figured out the tank part yet. I should buy Vin's secondary that he has.

Flywheel resurfacing I'll most likely have done at Grammer Gates machine shop over in geneva, it cost me $40 bucks and they did it while I waited for my Vr rebuild.

-T

[VRsuper6]

Flywheel resurfacing I'll most likely have done at Grammer Gates machine shop over in geneva, it cost me $40 bucks and they did it while I waited for my Vr rebuild.

-T

you should ask them to show you how when they do it. so that way you would have a valuable task that you can accomplish yourself oneday for someone:smile:

[meatwad!!]

you should ask them to show you how when they do it. so that way you would have a valuable task that you can accomplish yourself oneday for someone:smile:

is this a hint?

[FusLit]

you should ask them to show you how when they do it. so that way you would have a valuable task that you can accomplish yourself oneday for someone:smile:

I watched them do it last time, I don't have the machine they have to do it. It's specific to flywheel resurfacing from what I can tell.

I'm sure you could do it with a mill/lathe but in this case, I'll just take it to them for the $40 bucks. I'm out of space in the garage as it is ...

:)

-T

[VRsuper6]

is this a hint?

i was tihnking it could be at one point, as of now, my only VR has an alluminum l/w FW already so no need as of yet...

T, it is cheap and definetly worth it for them to do it. just kinda prodding to see you use all dem tools you got der :wink:

[FusLit]

i was tihnking it could be at one point, as of now, my only VR has an alluminum l/w FW already so no need as of yet...

T, it is cheap and definetly worth it for them to do it. just kinda prodding to see you use all dem tools you got der :wink:

well, I made the piston protrusion tool for this project with them so I knew which thickness head gasket I needed to order. :icon_smile:

More stuff will be fabricated have no fear but I gotta focus on getting the garage unburied.

-T

[FusLit]

I drilled a few (6) steam holes in the head and block to compensate for the extra holes that the new 1.9 aaz gasket has. (supposed to help alleviate air pockets from what I've read)

Headgasket is on and torqued down.

http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20081214_headgasket/IMG_1472_640.JPG

http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20081214_headgasket/IMG_1473_640.JPG

You can see here the one spot to the upper right that the gasket doesn't seal, so I used some high temp copper gasket seal and a piece of innertube to fill in the gap. Again something else I've read works well, we'll see I suppose.

http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/20081214_headgasket/IMG_1475_640.JPG

I need to pickup some stuff that will allow me to clean up my ip and some other bits that I want to clean before putting on the engine.

-T

[VRsuper6]

you should et a parts cleaner :cool:

[FusLit]

you should et a parts cleaner :cool:

Yeah, I've got a crappy one, I need to get some new solution for it. I'm thinking about setting up some sort of media filter on it to help clean the cleaning solution from chunks.

I'm thinking about trying a different cleaning approach and instead use a Trisodium Phosphate (TSP) solution in a pot that I can put on a turkey burner type thing. Boil the grease and paint away. I've read a few different threads of people who use this method with good success.

-T

[VRsuper6]

sweet. maybe we can experiment and make some stuff shiny for my build.......one day :wink:

[BUNNYLOVE]

Todd, you might want to try one of those agricultural filters on your parts washer. They have a SS screen inside that might do the trick and it would be easy to clean. Its the same part Joe had on his CC vent setup. I'm using one too.