rebuilding my vw diesel engine

[jimfoo]

My Rover hasn't had good luck since I put a 1.9l VW IDI engine in it. First, only a month after I put it it, someone cut me off and totaled the rover, a 1966 88". I rebuilt the whole thing, including the engine as it ran badly after the accident, but it would get very hot on hills. Not the best thing for an alumin(i)um head. But it ran, for maybe 5 months. First a hydraulic hose I had made up for the remote oil filter leaked at a swivel fitting while on a long trip. I had about no oil when I finally noticed. Then I found the hose from the ir filter to turbo had disintegrated from battery acid fumes, but not before loads of dust had been sucked in. It didn't last long after that with the rings in 2 cylinders worn to about half their normal width, a piston losing a chunk and a pre-chamber beating itself to death on the piston.
I have since found that a TDI head and pistons will fit in my IDI block, so I am once again rebuilding. I have just started getting parts together, and details will be on my web page at mods
My 2.25 I took out had 42 hp and 83 ft/lbs torque, my IDI had 80 hp and 122.5 ft/lbs of torque. It will be interesting to see what this new motor will produce.
I had to design the adapter myself, so I doubt any of you have a VW Diesel, but you might find the process interesting, so I am posting it.
Wish me luck!

[Funrover]

Good luck!

[Elemental]

Very Interested... 03 Jetta here.

[jimfoo]

Everything is down at the machine shop. The head is done, and luckily all my AAZ valvetrain components swapped to the 1Z/AHU head which I bought bare. The pistons will get ceramic coated as soon as the machine shop is through boring and balancing everything. My old injection pump is getting sent to Giles at Performance Diesel to be converted to a mechanical TDI pump. He is on the expensive side, but from everything I hear, he is THE VE pump god. I'm hoping to have it running again sometime in Jan with more power and mileage!

[jimfoo]

More pics are up. I'm still waiting on parts, and will now be looking for turbo parts after I finally pulled mine apart to see the damage.

[jimfoo]

I have been working on my project for untold weeks now. Yet due to the intricacies that are my stocks which fund my project , and then waiting for parts to see that they will work before I order other parts, and due to me still not working, I have been sitting on my butt for untold hours per day surfing the web as it has been too cold and snowy to do something useful like clean my garage so that I have room to work on my Rover when the purchase and acquisition of all necessary parts is done. However I have finally been able to pick up my block, my ceramic coated pistons, my head and my crank. However due to incompetency at the machine shop, the ramp type keyway on the nose of the crank for the timing belt gear which was supposed to have been filled with weld, then ground into a D shape for the new sprocket was mostly just ground down. GRRRR!!! So I actually spent the morning building the crank up with weld, slowly grinding it down with a dremel, and repeating the process until I finally got a good tight fit. I did also put a piston in to measure protrusion as I wasn't positive if TDI pistons were close enough to the same height as the IDI ones. It would have sucked if they were too tall and I had to machine my ceramic coating off. So now I can finally order my head gasket of the correct thickness, as well as the last remaining gaskets and seals and finally start putting it together. Then all I need is to get the injection pump modified. It has been WAY too long since I've driven my Series, and I really miss it. New pictures will follow as soon as I start assembly.

[jimfoo]

It was barely warm enough to paint outside today, so the block got a coat of Detroit Diesel Alpine Green, as that is close to the stock Rover engine color.

I decided to paint the valve cover green too rather than leaving it the stock black. Pulleys however get black.
Or go here for the whole project so far.

I got my pistons ceramic coated, which will hopefully reduce engine temps a little. I also tried grooving them, which is supposed to help with low end torque and mileage. I have my doubts, but I figured it can't hurt.

[stolenheron]

looks like your definetly making some headway!

[jimfoo]

Crap, someone just reminded me that I need a different valve cover. Hopefully I don't have to get it from a dealer.

[ArmyRover]

junkyard my friend junkyard

[jimfoo]

Not easy to find anything for this year head as it was only produced for about 2 years. But I might have found someone with one.

[jimfoo]

It lives!! The engine at least. I have lots of new pics upfor all the work I've done so far. I know the timing is off even though it's set where it should theoretically be. I'm thinking it's due to the higher 220 bar injectors I'm using, so I may have to go to the dyno once more and adjust it there. Still some work to do before I can drop it in though.

[KevinNY]

Amazing how funky they sound without an exhaust system. I thought something was all mofungo when mine sounded sort of like that until the exhaust system went on.

[trecker]

amazing build... hope this car parts link could help you out..

[jimfoo]

Hopefully I am done buying parts for a while.