Crazy Hungarian
Member
Greetings. Long time lurker, first time poster and just joined.
As Uberhare can vouch, I'm by no means new to dubs....just new to diesels...and even newer to TDI's
So here's my daily.
1992 Jetta TD with roughly 285K kms on it....just broken in really.
In winter mode after a trip to Ikea
And here in summer mode
I bought the car last March from a Police officer east of Toronto.
Over the past year, with lots of parts from Perjad @ Precision Tuning, I got it up to snuff. Sadly, around Christmas this year, the injection pump started leaking. The smell of the leaking fuel when I'm stuck in traffic is just unbearable. So something had to be done. And while I love the raw simplicity of the IDI, the additional performance and economy of the TDI was really appealing. So the decision I had to make was pay Gilles for one of his super pumps (and because I lacked the timing tools and the know-how) pay him to Re and Re the pump, or close my eyes, and jump into the realm of TDI's. I'm not a finesse mechanic by any means, more of a rip and replace type person. Plus I've done a few motor swaps on VW's in the past, so I figured why not take a TDI from a nasty, rusty mk3 Hecho en Mexico POS Jetta and toss it into a nice clean German made mk2 shell.
So I bought a donor from off VWVortex.
And got to work stripping it
So here's where I stand now.
I have everything needed from the donor based on this checklist from G60ING http://forums.tdiclub.com/showpost.php?p=2560652&postcount=35
Everything I needed that wasn't on the donor, like the B4 Passat TDI pedal cluster and a few other misc widgets were procured from The Source here in Toronto.
And I'm slowly but surely going through the bits and pieces to make sure that everything I have is cleaned, detailed and what should be replaced is.
So, for example....the CTN code 02A tranny:
Before:
Ready for paint:
And of course, while I had it apart I added new flange seals, a new input shaft seal, some new shift tower linkage bits and 2L of Amsoil synthetic gear oil.
So yeah, I'm in no rush to do this swap, just wanna do it once and do it right.
Should have pics tomorrow of the progress on the longblock itself.
I tore into it over the past week, removed the intake and exhaust manifolds...man of man there was lots-o-carbon in the intake ports and manifold
Doing the timing belt and tensioner (with Uberhare's help), already did the rear main seal and I'm in the middle of trying to get the blasted injectors out of the head so I can have my local truck shop Diesel Doctors check them, with the eventual goal of tossing some nozzles on them
So yeah, that's kind of where I'm at right now.
What I'm thinking in terms of plans (and I'd REALLY appreciate some feedback on this from you seasoned vets)
For the clutch I sourced a single mass lightened flywheel with a Sachs VR6 clutch kit, I know people with Turbo VR6's and this clutch will hold with them no problem, so it should be good for what I have in store.
What I have in store. Rocket Chips software, 205 Nozzles from Kinetic and the hybrid K03/K04 Turbo from Kerma TDI
http://www.kermatdi.com/servlet/-strse-428/-dsh-K03-fdsh-K04-Hybrid-turbo-for/Detail
My rationale being that I don't want a huge smoke cloud of a car (so the 216 nozzles are out of the question), and I want to retain the stock engine mount on the back, so the hybrid VNT turbos are out due to spacial constraints.
What I am wondering about is whether or not I should delete my EGR?
Ok, so that's the starting point.
Off we go.
As Uberhare can vouch, I'm by no means new to dubs....just new to diesels...and even newer to TDI's
So here's my daily.
1992 Jetta TD with roughly 285K kms on it....just broken in really.
In winter mode after a trip to Ikea
And here in summer mode
I bought the car last March from a Police officer east of Toronto.
Over the past year, with lots of parts from Perjad @ Precision Tuning, I got it up to snuff. Sadly, around Christmas this year, the injection pump started leaking. The smell of the leaking fuel when I'm stuck in traffic is just unbearable. So something had to be done. And while I love the raw simplicity of the IDI, the additional performance and economy of the TDI was really appealing. So the decision I had to make was pay Gilles for one of his super pumps (and because I lacked the timing tools and the know-how) pay him to Re and Re the pump, or close my eyes, and jump into the realm of TDI's. I'm not a finesse mechanic by any means, more of a rip and replace type person. Plus I've done a few motor swaps on VW's in the past, so I figured why not take a TDI from a nasty, rusty mk3 Hecho en Mexico POS Jetta and toss it into a nice clean German made mk2 shell.
So I bought a donor from off VWVortex.
And got to work stripping it
So here's where I stand now.
I have everything needed from the donor based on this checklist from G60ING http://forums.tdiclub.com/showpost.php?p=2560652&postcount=35
Everything I needed that wasn't on the donor, like the B4 Passat TDI pedal cluster and a few other misc widgets were procured from The Source here in Toronto.
And I'm slowly but surely going through the bits and pieces to make sure that everything I have is cleaned, detailed and what should be replaced is.
So, for example....the CTN code 02A tranny:
Before:
Ready for paint:
And of course, while I had it apart I added new flange seals, a new input shaft seal, some new shift tower linkage bits and 2L of Amsoil synthetic gear oil.
So yeah, I'm in no rush to do this swap, just wanna do it once and do it right.
Should have pics tomorrow of the progress on the longblock itself.
I tore into it over the past week, removed the intake and exhaust manifolds...man of man there was lots-o-carbon in the intake ports and manifold
Doing the timing belt and tensioner (with Uberhare's help), already did the rear main seal and I'm in the middle of trying to get the blasted injectors out of the head so I can have my local truck shop Diesel Doctors check them, with the eventual goal of tossing some nozzles on them
So yeah, that's kind of where I'm at right now.
What I'm thinking in terms of plans (and I'd REALLY appreciate some feedback on this from you seasoned vets)
For the clutch I sourced a single mass lightened flywheel with a Sachs VR6 clutch kit, I know people with Turbo VR6's and this clutch will hold with them no problem, so it should be good for what I have in store.
What I have in store. Rocket Chips software, 205 Nozzles from Kinetic and the hybrid K03/K04 Turbo from Kerma TDI
http://www.kermatdi.com/servlet/-strse-428/-dsh-K03-fdsh-K04-Hybrid-turbo-for/Detail
My rationale being that I don't want a huge smoke cloud of a car (so the 216 nozzles are out of the question), and I want to retain the stock engine mount on the back, so the hybrid VNT turbos are out due to spacial constraints.
What I am wondering about is whether or not I should delete my EGR?
Ok, so that's the starting point.
Off we go.