G-8VXWWTRHPN mk1 1.9TDI in progress - VWWatercooled Australia

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mk1 1.9TDI in progress

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  • mk1 1.9TDI in progress

    Hello diesel people.

    For those that arent frequently browsing the mk1 forums you may not know im trying to build a TDI mk1.

    I'll be keeping the tech chat in this new thread in the diesel section to keep the forum more organised.

    I'm using a 1.9 1Z which comes in late 90's mk3, passat, T4 etc in the rest of the world.

    The engine was imported without an ECU etc. so Ill be ditching the electronically controlled pump and going with the so called "M-tdi" option which uses the older mechnically controlled Bosch VE pump with a TDI camplate and rotor which bring up the pressure to suit the TDI engine.

    I bought an M-tdi ready pump straight from a pump-builder in the US which uses an AAZ (1.9td indirect injection) pump body. This should hopefullly get the 1Z running and then I cant play with governers and timing to get the car running how i want it.

    this is the 1Z in all its glory this morning.. after a bit of a tidy up and pulling off all that pesky electronic wiring



    then good bye to the evil electronic controlled injector pump



    this is the 1Z electronic pump on the left, and my rebuilt AAZ (indirect injection 1.9) pump on the right. The AAZ pump has TDI camplate and rotor in it, which makes it able to run higher TDI pressures, but without needing an ECU to run the pump, making this a so-called "M-TDI"



    fitting up the new pump



    here is my cheapo chinese turbo. It's a copy of a k04 turbo. I dont think i'll be using it. Ive got some other options as i have a 4 stud manifold from my 1.6 td which means i can use a k14 or T3. The 1Z came out with the both the k03 or k14 originally.




    Currently held up as I need a new injector pump pulley to fit the AAZ pump. Should be able to get one from the states pretty cheap.
    TDI mk1 on the road!!


  • #2
    Love it man. Subscribed...

    APR Tuned | KW Suspension | INA Engineering | Mocal Oil Control |
    Website: http://www.tprengineering.com
    Email: chris@tprengineering.com

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    • #3
      That was fast preen.
      BTW. I fixed my alternator mount problem. I'll show you when it arrives. It will be posted up here
      TDI mk1 on the road!!

      Comment


      • #4
        awesome!!!! i like where this i going....

        say NO to cheap chinese crap!!!!
        VW: it aint just a car, its a way of life
        There are few things more satisfying in life than finding a solution to a problem and implementing it
        My Blog: tinkererstales.blogspot.com.au

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        • #5
          Originally posted by mollins View Post
          That was fast preen.
          BTW. I fixed my alternator mount problem. I'll show you when it arrives. It will be posted up here
          I've got my eye on the ball see...

          Yeah i'll be interested to have a look. What did you end up going with?

          APR Tuned | KW Suspension | INA Engineering | Mocal Oil Control |
          Website: http://www.tprengineering.com
          Email: chris@tprengineering.com

          Comment


          • #6
            Originally posted by Preen59 View Post
            What did you end up going with?
            its in the post. patience. time will tell.
            TDI mk1 on the road!!

            Comment


            • #7
              Compression ratios?

              Looks good!

              How does the M-Tdi pump cope with the reduced compression ratio of the 1.9 ECU controlled motor? Without looking it up, I think it's 19 or so :1 The revised cam plate will alter the volume and perhaps the timing/length of injection.

              Also, the injectors are different. What mods are necessary?

              There's probably plenty of scope to play around with boost pressure and other turbo tweaks. Are you going to intercool it?

              Good to see one of the original VWWA members doing something radical. And even better, including we dieselers in the updates!

              Comment


              • #8
                Nice work, love to have the time to pull the donk out like you did on the MK5 and mess with it.

                Hope you have some decent intercooling ideas to back up all the great work thus far, and allow you the ceiling for said boost pressure tweaking!

                Look forward to seeing your progress young oiler
                2014 Skoda Yeti TDI Outdoor 4x4 | Audi Q3 CFGC repower | Darkside tune and Race Cams | Darkside dump pDPF | Wagner Comp IC | Snow Water Meth | Bilstein B6 H&R springs | Rays Homura 2x7 18 x 8" 255 Potenza Sports | Golf R subframe | Superpro sways and bushings | 034 engine mounts | MK6 GTI brakes |

                Comment


                • #9
                  Originally posted by cetane View Post
                  How does the M-Tdi pump cope with the reduced compression ratio of the 1.9 ECU controlled motor? Without looking it up, I think it's 19 or so :1
                  The revised cam plate will alter the volume and perhaps the timing/length of injection.
                  Also, the injectors are different. What mods are necessary?
                  correct, comp ratio is lower at 19.5:1
                  the pump doesnt have any feedback from the engine, just sets a pressure curve for each injector line. I am using TDI injectors and therefore the breaking pressure will be the same as if it was using a 1z pump. The timing will be the hard bit. I think the direct injection will require me to time the pump differently, but i'll deal with that when I come to it


                  There's probably plenty of scope to play around with boost pressure and other turbo tweaks. Are you going to intercool it?
                  yes will be intercooled. will be running 10-20psi to start with
                  TDI mk1 on the road!!

                  Comment


                  • #10
                    Originally posted by mollins View Post

                    yes will be intercooled. will be running 10-20psi to start with
                    thats a pretty big range "to start with"

                    bugger it. go straight for 20psi! hahahaha no don't, gah, im sure you'll figure it out


                    i like volkswagens
                    My blog: http://garagefiftythree.blogspot.com.au/

                    Comment


                    • #11
                      goddam it i wanna see 30psi
                      VW: it aint just a car, its a way of life
                      There are few things more satisfying in life than finding a solution to a problem and implementing it
                      My Blog: tinkererstales.blogspot.com.au

                      Comment


                      • #12
                        the differences between the 1z and aaz (in my mk3) aren't so great, especially in the bottom end, with crank, rods, block all identical. the boost pressure that mike will be able to run is safe enough at 20 (its fine on my aaz), even without an intercooler (though not optimal).

                        i suspect we may be "dynamically" timing the enine once its running in order to get it going well.

                        theres lots of fun to come.
                        '07 Touareg V6 TDI with air suspension
                        '98 Mk3 Cabriolet 2.0 8V
                        '99 A4 Quattro 1.8T

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                        • #13
                          Originally posted by gldgti View Post
                          theres lots of fun to come.
                          I'm on the edge of my seat..

                          APR Tuned | KW Suspension | INA Engineering | Mocal Oil Control |
                          Website: http://www.tprengineering.com
                          Email: chris@tprengineering.com

                          Comment


                          • #14
                            stick a big intercooler on it and a bigger turbo then that, they are fairly restricted stock.

                            Your living my dream of a TDi in a Mk1, but I would prefer the electronic pump myself, way easier to work on in general IMO. (based on the bigger stuff I work on)
                            88' Volvo 760GLE
                            88' Volvo 740 Turbo
                            Originally posted by tosspot
                            Also, drags are the worst form of motorsport. Who'd want a fast drag car for their street car?

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                            • #15
                              Originally posted by Volvo Driver View Post
                              stick a big intercooler on it and a bigger turbo then that, they are fairly restricted stock.
                              i have front mount cooler, much better than the stoopid mk3 side setup ... and the turbo will be a K04 which is a fair whack bigger than the standard k03 or k14.

                              Originally posted by Volvo Driver View Post
                              Your living my dream of a TDi in a Mk1, but I would prefer the electronic pump myself, way easier to work on in general IMO. (based on the bigger stuff I work on)
                              you can have your electronic pump. makes sense with a stock setup car. i had no loom and no ecu. so mechanical it is. plus i like things i can see and adjust and tamper with, none of this chip flashing or laptop-in-car-crap. The Bosch VE pump is an absolutely amazing piece of engineering. The more i play with them the more it blows my mind.

                              this way, i can remap my fuel and advance curve any day for free!!
                              TDI mk1 on the road!!

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