Turbo Diesel Cabriolet Project (with head porting pics)

[Jarred]

I have to say, I wasn't too sure about getting a cabby, but after owning one for a while, I have to say it's pretty good! WIth factory sways allround (and coilovers) it handled quite well!

Can't wait to see the rest of the project develop.

[sparkie]

Hey gldgti, I have just bought a petrol Cab, pick it up at the weekend, and I also want to diesel it. I have a choice of 1.5 NA 4 speed (mk1), 1.6 non intercooled turbo 5 speed (mk2), or I could retire the Mk3 Tdi car and put the engine in the Cab. What would you suggest?

[gldgti]

to be honest hte 1.5 in the cabby is pretty slow. Our 1.5 is a good runner and seems to make as much power and torque as any I've driven, but in the cabby it was quite slow.

1.6TD is a good option. BTW - you can use the cabby gearbox if you want. I think a lot of cabby's have AUG which is a bit of an aweful set of ratio's for a diesel, but still better than a mk1 4 speed in my opinion.

Its a much bigger effort to swap in your TDI, unless you want to build/purchase a M-TDI pump.... then its as easy as either of the opther options.

I would go for 1.6TD for simplicity.... amazing that you have one!

[JustMark]

Here is the top gear vid if you havent seen it yet...

gldgti

I'd love to see some photos of you flipped manifold. Or a photo tut if you know of one. or what is required...

I've just sourced a 1.6td that i am currently putting into my golf and i'd love to give it a bit more go. Ive got an A2 petrol manifold that i was going to bang on my 1.5 with some headers, but now ive got the TD i'd love to put it on that.

Mark

[gldgti]

Mark,

Unfortunately I havn't got around to doing the manifold this week so your in luck, I will detail it for you when that happens.

[JustMark]

That would be awesome

Thanks mate

[gldgti]

sorry guys, the project stopped for a few weeks while I sold my mk3 and we only got back into it last weekend. The simple engine swap has turned into a bit of an engine rebuild, with the head coming off and stuff so hopefully i'll get some pics happenning and progress to show this week for you all.

main thing is that this one has a deadline on the end of september 'cos I want it back driving with the 1.9 turbo before rego comes around again!

[gldgti]

so got busy today

carbide rotary burr tool....


the 1.9 8V head flows pretty well, but theres always something you can do to imporve things... the most beneficial place is right near the valves on the inside of the radius. There's a pretty obvious ridge there that i tried to photograph.....


and after some shaping....


after that, I gasket matched the intake ports.... normally this isnt the best way to do it, but I actually used the witness marks on the head and manifold from where thay had been bolted together for so long.... ought to be pretty reliable. THe fact I had to take a lot less off the manifold compared to the head goes to show that the stock parts are'nt perfect....

nowhere was that more obvious than the exhaust ports.... a full 4mm narrower and 5mm shorter than the ports on the exhaust manifold.... so plenty of blending out there...

cleaned head


I like what the block casting says


more to come tomorrow!

[gldgti]

Head is back on the engine today. Bottom end is all together. Pretty pictures to come tomorrow.

Only had to put a set of new big end bearings in, other than that it all looks great for boost.

[sports racer]

Got my fingers crossed for you.