AHU TDI engine build

Today turned out great after a slow start with at trip with Grover (my blue 85 F250) down to the shipping terminal in Eugene to pick up a TDI engine/peripherals for my next TDI conversion project.  The afternoon was all about finishing the build of the TDI engine that will be going in my Eurovan.  Here's some pics of the process:

Short block fitted with new 79.97mm Nural pistons.  Block bored/honed to 80.01mm.  New wrist pin bushings, I-shaft bearings, Glyco rod and main bearings. Sexy.

And with Raceware studs installed.  Very sexy.

My intention with this engine build and project is to maximize performance and build a sort of a "show vehicle" Eurovan so people can see what the potential of this engine in a Eurovan is.  Any time an engine is being built for above stock power output, head studs are a smart investment to keep that head 'glued' to the block under high boost/high power output levels.  Otherwise regular old TDI spec head bolts are perfectly fine to use.





Measuring piston height projection--a sun smote on the dial indicator face, a sign from the VW divinity?

Now it's time to start dressing the head.  We ship all our heads to Aluminum Head Rebuilders in Portland, OR for complete OE spec rebuilds.  They're the best in the biz--period. 

Long block stage.  Head gasket is installed on block,  head is installed, torqued to spec and peripherals attached.

Engine is fitted with factory Bosch T4 TDI injectors from Germany with .216 nozzles (basically PP764s).  These came on the 5-cyl 150hp TDI engine in Europe.  The intake manifold is a high flow intake from a PD150--the highest power output 4-cyl TDI engine out there, but not necessary to fit in a Eurovan.  Exhaust manifold is stock AHU with EGR delete blocking plate and pre-turbine EGT probe, both non-essential features for the EV installation.

               

       

 All in a days work!