Mk 1 TDI, The engine rebuild begins

Time to let you all in on what I've been up to lately. It should of been finished by now, but various commitments and the very poor weather we've had has slowed me right down. so far while working I've aways had dirty hands & lack of time, so I've not taken many pics

I've been bit by the track day buzz, and had a spare mk1, thought I'd put it to good use.
putting in a mk 4 TDI engine which is the ones in the early mk 4 GT TDI's, the engine transplant same work involved as a 1.8T (wiring/clocks/keys) but great consumption, loads of torque & bit different

Here's the car when it was still a 1300!




and my works desktop pic



engine as it today






as you'll see it fits in, found it not that simple that, no fancy home made mounts, I'm guessing VW spent lots of money researching the mk 4 mount, to help make them a smooth ride (isolating vibrations), and popping a TDI into a mk1 running a track/fast road set up need as much help as possible



YER THAT HELPS



this is bit better on the gearbox side



it was until trying to put on bolt on the drive shafts did i realised some of my measurements were slightly out, all that had to be cut out, and moved slightly!!
I've not got around to fully welding it up, getting everything trial fitted before a total strip down & tidy the bay up





Bit of a worry that sump sticking out (number plate is looks & krooked I know)


all of you that have done a 20VT will know how low those fragile ally sumps are to the ground, after changing loads during work time, and knowing the hassle of getting towed in, I decided it's not something for me

so I've come across one of theses - designed for 1.8T's















these are not a UK available part, special soucred by a good friend of mine, and I know where there is another 8 in the country, and who's got them- pm's welcome

It's a top half ally, bottom half steel. the bottom is where I've seen 99% damage caused by impact,

now I've had my own sump off couple times- last time changed the sealant/silicone to a different one, and reckon cos some the bolts were tighter than they should be, I might of got some on the threads unfortunately one of the harder to access bolts, hidden behind the gearbox decided it was going to round
had to be the worst one I've came across, and I'm not taking the gearbox off to fix






taking alternative action, almost ready to get sump off

 

Wicked project dude, i bet thats a hoot to drive round the lanes !!

 

Nice

 

nice little project going on there!

 

mk1 derv love it!

 

thats the future conversion niceone the sump looks a nice bit of kit

 

bit of an update on sump! got the bugger on


that looks bit more rugged
and sits only slightly further away from the ground, tried it on with the original oil pick up pipe, didn't touch it, then tried the shorter recommend pick up pipe, measured the difference and found the shorter pick had a greater clearance on 1cm (might on been 11mm!)

 

thanks for the comments, been keeping it on the back burner,ready to turn up the gas.
will be whipping it off to get a plate made for the oil return pipe, the TDI's go straight into the block

I'm having this weekend off, start working again Monday-

 

Very cool

How much power is the engine running?

 

the engine has been running 140+ prior to fitting in this mk 1, was rolling roaded at 135ish. turned out with the injection pump timing changed on fitting new injectors, and a very slight boost leak
all my planned engine mods still haven't been added, and thats still running the factory map!

Updated pic-

Power graph at wheels - 120 bhp/ 177 ft-lbs @ wheels very early in project!

 

Nice!

Would very much like to do a project like this at some point.

Keep us posted i guess!

 

What sort of power and torque are you hoping to be running.

Looks a nice project indeed. Keep us informed matey.

 

with my planned mods looking for 180-200 BHP/300lbs+, should be enough out of the mk 1 chassis

if anyones fitted Mk 4 ESP to a mk1/2 let me know

hoping to make the car usable not about silly power, best bit is the MPG figures in it's current set up driven hard returned 39.5MPG with a boot full of stuff parts!

hoping to get it running for E38 show, doubt it will be finished.

 

BuMp

nIcE SwAp

 

yep come on chris up dates!

 

might have the camera out today

spending all day on it today, most of the mk 4 wiring is hooked up to the mk1's switches, hydraulic clutch fitted but no reservoir fitted yet , modified intake manifold & shut off valve (a diesel thing), intercooler & rad fitted
the hybrid sump ( see above) should be getting baffles fitted today.

 

Was about to yelp 'traction!', but then noticed

 

refreshing

 

todays been a long old day, been a case of finishing of some of the interior wiring, still a mess but now in organised sections! . all thats left is to get wiper motor working off the mk 1 switch on mk 4 wiring- no rush then


Pic of original restrictive inlet


now ditched !


my new inlet, more at home in a mk1 (notice the slight mod? )





now i need to something to connect the hose to, how about this??





now acts as a air shut off valve on killing engine, with duck tape as a temp support - main thing is works



Hydraulic clutch, mk 4 brake pedal switch, & Drive By Wire accelerator pedal mount


yes the pedals look don't look straight

just got to get the bugger running!!

Seraph : not only do i need some form of traction, but some control over my poor driving skills

still on the look out for a ABS pump with ESP - got all the ESP motion sensors sorted