allroad V6 TDI slow build

[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.

[gldgti]

Got one head together today and all the turbo stuff done.
https://youtu.be/foHDqWEHeWk


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[gldgti]

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[gldgti]

So what happened here with my allroad build?
Well after a big weekend putting the engine back together with all the new bits, I ended up pretty deflated when I only had compression on 3 cylinders.
I got the ****s with it and bought a v5 bora to drive in the meantime while I figured out what was wrong.
After a month I built up the gumption to pull the heads off again, assuming I'd rushed the valve job and buggered it.
So, last weekend I re lapped all 24 valves and vacuum tested all of them before torquing down the heads again, assured they would be perfect.
By Wednesday night I had the timing belts back on, so I could turn it over by hand and check for compression.
Imagine how I felt when this time, I only had compression on one cylinder.
It's then I realised that I was probably not my lapping skills that were the problem. Rather, the tolerances of all the new parts (cams, valves, rockers, lifters) adding up to hold the valves open!
Today I confirmed this by pulling vacuum on the ports with the cams torqued down, and then after loosening the bearing caps 1/4 turn... That's right, 0.25mm is all it took to close the valves.
I didn't particularly want to pull both heads again ( $300 in bolts and gaskets each time) so I could grind the valve stems down, so I found I could grind down the tip of the cam follower instead and achieve the same results. Ask me if this was a good idea in a year or so I guess! But I can replace the followers easily any time... Pulling the heads is something I just don't want to do a 3rd time right now!

Anyway, I managed to modify 12 followers on 1 head this evening, and get it all back together so that I could pull vacuum on the intake ports with the cams torqued down and finally, success!
I'll do the other head tomorrow and put the car back together next week.
So relieved. Damn tolerances!
I did measure the new valves, they are all within tolerance, however they are all at the higher end of the range.

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[brad]

Well done you. Character building to say the least.

[gldgti]

Yes, that's one way to describe it!
I am pleased to report good compression when turning over by hand now. Finally I can put it back together!

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