allroad V6 TDI slow build

[gldgti]

Got one head off today, looks pretty good apart from the ****y cams. Still can see honing marks in the cylinder bores after 250,000km.
Working on this beast is totally different from a golf. There's twice as much work to do, but its heaps easier work - not back breaking or awkward.
But I've got 6 40 litre plastic tubs labeled with various zones so that I can put it all back together!

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[h100vw]

Got one head off today, looks pretty good apart from the ****y cams. Still can see honing marks in the cylinder bores after 250,000km.
Working on this beast is totally different from a golf. There's twice as much work to do, but its heaps easier work - not back breaking or awkward.
But I've got 6 40 litre plastic tubs labeled with various zones so that I can put it all back together!

Sent from my Nexus 5 using Tapatalk

Good job it's not been tuned!!

[anthony--t]

Hey! You're doing all the fun stuff without me haha. Good to see you're getting it done!

[Ryeman]

Any 'step' on the upper bore area?

[gldgti]

No the bores are excellent, just a wee bit of carbon above the ring scrape area.
Yes gavs I am glad this is happening now! I also have a K04 bv50 that I will try and fit whilst this is all happening, so hopefully when it comes tuning time we can crack 250hp. That would be nice

I've got quite a few more weekends work on it so don't sweat Anthony, plenty more to do

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[gldgti]

Just ordered a heap of o rings so I can renew them all. This engine is gonna be like new when I'm done!

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[gldgti]

Gav - since I didn't get a chance to log anything before this happened, is it going to be a problem to do a tune with the new turbo? I'm pretty sure if I set up the k04 properly, it should run just fine on the stock tune - if I take some logs then, should be ok to make a tune from that, correct?

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[gldgti]

been doing some measuring and drawing tonight...


The weird little tag on the bottom of the bv50 inlet flange will allow me to align each end of the adaptor so the new turbo will be oriented exactly as per the old one. There is around 20mm "height" difference, between the shaft and the inlet flange on each turbo, which means if my adaptor is 20mm tall, the new turbo wont even stick up any higher than the old one. I should therefore have plenty of room!

[h100vw]

Gav - since I didn't get a chance to log anything before this happened, is it going to be a problem to do a tune with the new turbo? I'm pretty sure if I set up the k04 properly, it should run just fine on the stock tune - if I take some logs then, should be ok to make a tune from that, correct?

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In theory, the ECU will see the boost pressure and control the turbo accordingly. It might be necessary to adjust the actuator if there's boost spikes. In fact it could be sensible to back it off and adjust it up once you get the car back on the road.

Gavin

[gldgti]

progress...

a little progress this weekend. Managed to get one head fully dis-assembled and cleaned. First challenge was finding a suitable valve spring compressor. Looked around at whats available, didnt like anything. Then I realised that I had 90% of the makings of a very sexy valve spring compressor already bolted to my workbench - my little aldi drill press. I made a little compressor tool from some scrap steel to clamp into the chuck, then it was a simple matter to position the head on a block of wood below the drill head and simply crank down the drill head to compress each retainer/spring and remove the collets with a magnetic screwdriver. Its teh best way ive ever done the job, and the drill press requires no modifications at all. I'll try and take a video tomorrow for others benefit.

Also made a little injector removing slide hammer out of a bit of round bar, an M14 nut (front shock nut!) and an old wheel bearing for weight. (the injectors need to be pulled out this way, its the proper way to do it but i have no idea what the actual tool to do it looks like).

I did a little bit of smoothing of the ports on the passenger side head and got it all cleaned up and ready for reassembly. I had thought to do a proper port job but on looking carefully, the geometry is pretty complex and I think easy to muck it up. The 2 intake valves on each cylinder have 2 different roles - 1 hasa pretty direct port, the other is deliberately helical to introduce swirl in the chamber. So, rather than go nuts and cut a head of metal out with no regard, I've gone for a more minimalist approach - removing obvious casting lines, nodules and ridges, just basically smoothing out the port without changing the geometry. This didnt take long at all and there was really only a little to do on each.

So, pics!


This is just a shot of one of the bores.


Bake until shiny and new (80C to evaporate all the water leftover from the washing)

[brad]

I find the "less is more" approach to inlet smoothing to work quite well on modern engines. Remove the obvious dags, etc.

[gldgti]

I've made a couple of videos of my valve spring compressor
Part 1

https://youtu.be/vJ4_UbD7WfM

Part 2

https://www.youtube.com/watch?v=Aqx409lZx0U

[gldgti]

a little more progress this week... been working on odds and sods really, getting oil lines ready, a bit of cleaning (tonight), and some turbo adapter work:





old turbo - Garrett GT2052


new turbo - Borg Warner BV50:

[gldgti]

Got a giant box of audi engine parts delivered today.... woooo!

New turbo is basically sorted aswell - got the vane actuator conversion sorted and the oil feed and drains too.

First turbo swap TDI allroad in Aus???

[gldgti]

Whoops didnt realise those videos were private.... now public.