2.0 CR big turbo build, aiming to set WR

Macradiators.com

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2.0 CR 360hp
Yeah, really nice but it seems that i need to get good batteries. The duracell accu i have are not so good.
Engine block is done, now starting to reinstall oil pump, seals, rear flange, head studs.
 

Macradiators.com

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There is nothing easy about this project..
ARP must be machined on lathe to have a nice fit
and camshafts must be installed on the head after its bolted to engine block , real PITA

3 hole gasket needed it seems
i would of liked to use the 1.63mm i already have but it seems not

 
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Macradiators.com

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Injectors ready to go in
I still have to sort the bracket to hold them down in the cyl head.


 
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Macradiators.com

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I bought 3mm seals and removed 0.3
Previously i used double shims i had available that night in order to test it.
Not sure if reversing the holder is the smart thing to do as that has some preload on it..like a spring but its not like i have many options.
I will start directly with b8 injectors and cp3.
 

Macradiators.com

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There is a problem clamping b8 inj in the cyl head.
Any suggestions are welcomed.



In oem position there is not enough clamping of the inj. Down in the cyl head.
Reversed the spring force is so strong you destroy 6mm nut threads
The b8 injector seats 3.25mm lower than oem one.
 

Macradiators.com

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I wanted to get in touch with you Bobby. Longer studs dont solve the issue imo. Because there is a need of a spacer under the holder.
holder Reversed the pressure is so high i ruined a thread of nut.

A spacer under the holder in oem position could also be a solution , about 2.5mm spacer but more complex to machine
 

[486]

Top Post Dawg
Joined
Mar 1, 2014
Location
MN
TDI
02 golf ALH
piston bowl shape or injector spray angle different?

if it's sitting lower in the head that geometry might be different, unless the difference is on the top end.
Where the difference is dictates where you should adjust the shimming. Maybe more copper washer thickness, maybe washers under the flipped hold downs
 

Macradiators.com

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Now injectors seat identically to oem ones in the head, i mean injector protrusion out of the head, that's why i prepared the copper shims so i can spray like oem one.
Spray angle is identical.
 

[486]

Top Post Dawg
Joined
Mar 1, 2014
Location
MN
TDI
02 golf ALH
arright, then I'd flip the things over and use washers to set preload
flatten the hold downs a little bit in the press if you run out of stud length
 

Macradiators.com

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The beast is finally alive!
Many thanks go to Lucian who came to help me finish it faster. After taking the engine and gearbox off twice from the car, the last time i think we did put it back in under 60 seconds ;)
After 2 days of work and lot of fabrication for the new DSG gearbox we finally did it.
CP3 is running nicely and the dash is like a christmas tree ;) but so happy to hear the engine again.

Still need to finish the 2 piece downpipe with vband in the middle and we'll take it for a ride.

Last ..i have to remove those revo sh*t adhesives from the car.
 
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Macradiators.com

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Injectors properly seated and sealed on top to avoid fumes ;)
After 2 tanks i will have some upgrades for the engine and start tuning it.
 

DkZ

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Aug 23, 2016
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Scirocco 2.0tdi 197bhp ( 140 stock )
From each part of Romania are you my friend ? im currently working/living in Bucharest, would like to see and hear that beast when finished :)
 

Macradiators.com

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Timisoara ;)
Took it for a ride today, everything works nice.
The sound coming from the engine is different compared to before. Pools pretty decent starting from 2000-2200rpm.

Gearbox is awesome compared to dq250, so much smoother.
Tomorrow oil change for dsg and install of the polar fis.


 

Macradiators.com

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I need to put at least 1000km on the engine as everything is new (bearings, rods).
and make sure everything works fine.

So far no issues. Till i finish the 1000k there will be at least 2 new upgrades to the engine.
So far im very pleased in how its working.
 

Macradiators.com

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In the weekend i will make a video ;) now have to work to finish some details.

Got an error on gearbox, i dont really know what it means, hoping TVS Engineering can help since they are experts on DSG and conversion-retrofits.

Otherwise gearbox runs perfectly.
 

Macradiators.com

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Car is working fine, using it everyday.
I have some issues with Oil temperature and EGT, i cant read them in VCDS.
I have tried removing connector from oil sensor under the engine, no error on dash, this is strange and dangerous for the engine.

I tried different EGT sensor (took it from DPF) , still no reading, tried all channels.

If anybody has any idea on how to proceed next i'm all ears ;)

Here are the readings. -0.9 and -6







I think they were removed in the software somehow. For now i'm out of ideas :(
 
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