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Jan 10, 2017 16:09:39 GMT
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Connecting up the engine ancillaries presented some challenges The power steering was the most awkward. The original bracket didn't fit the new head. The power steering pump fitted to the 20v was also used to power hydraulically assisted brakes. A feature that I believe failed to catch on. Therefore it had an extra redundant circuit that would need dealing with. So, what to do? This was the answer; www.irozmotorsport.com/power-steering-pump-bracket-20v-conversions/a bracket made for next to nothing but worth its weight in gold if you haven't got the facilities to make such a thing. So this enabled me to fit the original 2.0 pump onto the new engine. The next problem I had was this thing  It was the wrong size to fit into the fuel lines on the new engine. Took a while to figure out what to do. In the end, I made adaptors using compression fittings. I was running out of time now and needed to get it running. One day I'd like to remake all the lines in kunifer. |
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Last Edit: Jan 10, 2017 16:10:12 GMT by pologaz
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Jan 10, 2017 16:22:42 GMT
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While I was messing with the fuel system, I decided to tackle the problem with the fuel injectors.
The fuel injectors are the weakest link on this engine. The engine management on this engine is an early adopter of sequential fuel injection. It only fires the fuel into the manifold a predetermined amount of time before it is needed. This means that it fires in very short pulses, but at a high delivery rate to compensate for the pulse time.
This is supposed to make things better in some way. Whether its fuel consumption or power I am not sure. On earlier electronic fuel injection engines, all the injectors fired at the same time, so the amount of dead time between the fuel entering the manifold and entering the cylinder would vary, which may lead to undesirable things happening like fuel drop out or larger droplets coalescing. I have made some of this up as I've gone along. I'm sure they knew what they were doing.
Anyway. The injectors had to be designed specially for this engine. The result was a very high cc (for non-turbo) injector (305cc) and high fuel pressure for efi of 4.2bar. To make them respond quickly they were also low impedance, which meant they get hot.
TBC
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Last Edit: Jan 10, 2017 16:23:51 GMT by pologaz
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This engine's pretty well catered for in aftermarket tuning parts. a company called 034motorsport started doing a bosch injector conversion kit some years ago. The original injectors are made by hitachi. When they were built, the technology was in its infancy and 20 years of development by bosch have made it possible to make a much better, high impedance injector suitable for sequential injection. To use high impedance injectors you need to remove the resistor pack for the low impedance injectors and join all the wires together from it. No biggie, as long as the total resistance of system doesn't decrease any or increase too much, no problem. The kit was expensive though, so I started to look for alternative sources for the injectors. After trawling through many injector tables, I found some volvo T6 injectors that did the job for a fraction of the cost, which came in a very fetching shade of pink  Here they are installed on the manifold.  |
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Last Edit: Jan 11, 2017 8:31:27 GMT by pologaz
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Nearly there now, but I still had to sort this out:  Took me a while to get my head around everything, in the end I unwrapped the original 2.0 engine loom and the 20v engine loom, removed everything that wasn't needed and rewrapped it into one loom. Luckily I was able to get hold of all of the wiring diagrams and suss out what I needed and didn't need. There was quite a lot to throw away from the 20v loom. I had a lot of help from the knowledgeable folk over on Classic Audi. They have my eternal thanks. After a very long weekend, of mostly doing this:  removing plug heads to get the looms through the bulkhead I finally got it running on the Sunday night. |
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I'd cobbled together half an exhaust, just to get it over to longlife. I can unbolt and bolt things together but not make them. I wish I could. I'd manage to finish the car with about a week's MOT left. I just needed it to get to longlife I couldn't decide on a tailpipe, so I decided to go to a factory look as I was sure not to ruin it doing that.   As you can see the car had been stood for a while by this point! |
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I had to leave the mot for a few weeks as I had a 2 week holiday booked. I picked the car up the day before we left. Could not have cut it any finer. As soon as I came back, had the car booked in and it flew through. With only 52 miles covered since the last one, I should hope so! I took it for a drive to work and wow what a difference! I did however, have a few teething problems Small coolant leak from the rad fan switch. Needed a small amount of tightening. I always worry I will break the radiator when I do this, but it seems to be ok now! Gear linkage - I found when I refitted the linkage that someone had clamped the shift rod with the clamp only half on the rod, so the clamp over-crushed meaning it couldn't be pushed further on. This had caused me some problems when driving in the past, namely it would occasionally not fully engage 3rd gear and jump out again (not good when towing a trailer uphill!) With the clamp fixed everything seemed to be ok. A bit of a relief as I was worried there was a fault with the gearbox. The clutch needed a second bleed, i was biting right on the floor and sometimes not letting me get any gears. Decided I needed to fit some worry gauges  |
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Here's what the old engine sounded like And the new one  |
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Last Edit: Jan 11, 2017 8:54:13 GMT by pologaz
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The car was finished about two years ago. This time last year I had it rolling roaded  Actually a bit disappointed with that. The engine was designed to run on 98RON fuel, and I believe its stock power of 170bhp is derived from that. I haven't bought high octane fuel in at least 10 years. Perhaps I should and run it again. It's either that or the fuel injectors aren't big enough! It still has to earn its keep from time to time  |
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Last Edit: Jan 11, 2017 9:01:02 GMT by pologaz
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ooooh Love that 5 Cylinder noise. Good work!
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Jan 14, 2017 10:44:35 GMT
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Great conversion - very nice car. I want one now!
Nick
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1967 Triumph Vitesse convertible (old friend)
1996 Audi A6 2.5 TDI Avant (still durability testing)
1972 GT6 Mk3 (Restored after loong rest & getting the hang of being a car again)
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stevietuck
Posted a lot
Never argue with idiots,they drag you down to their level then beat you with their expertise!
Posts: 1,350
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Jan 14, 2017 19:38:50 GMT
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Boxy, square loveliness
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Jan 15, 2017 21:41:10 GMT
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Funny, just reading passat and 20v kept me from taking interest in this thread, as I thought it was a newer passat type. I don´t care too much for engines, I´m more interested in body shapes. Since the b2 passat is my alltime favorite generation of passats in terms of exterior design, I was quite surprised when I read the year of it this morning: 1987! Exactly my cup of tea! Thanks for this late write-up, lovely car, even with that lousy 1,6 diesel I once had, I would still like this car. I had four of them in my drivers career, that 1,6d and three 1,8. A 1.8 without end box does sound quite impressive, too, I can tell you, I bought my third one like that and drove it home a short bit on the autobahn. Ha yeah, it's the "other 20v engine" 😎 Thanks |
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am4nf
Part of things
Posts: 44 
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mk2 astra gte champion wheels? Much rareness
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ive got an s70 the same colour but the one drifting isn't mine
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am4nf
Part of things
Posts: 44
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Cant decide if they are or not now, they look too big to be 15s haha
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ive got an s70 the same colour but the one drifting isn't mine
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am4nf
Part of things
Posts: 44
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Nope I'm wrong  |
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ive got an s70 the same colour but the one drifting isn't mine
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They are B-star RA1680s - designed to replicate VW OEM BBS RAs but in a larger size, in this case 16x8 ET25
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Last Edit: Feb 8, 2017 15:44:41 GMT by pologaz
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Apr 26, 2017 14:45:04 GMT
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Another MOT passed. Should be at retro rides this year in this.   |
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Last Edit: Apr 26, 2017 14:56:16 GMT by pologaz
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Apr 26, 2017 15:23:37 GMT
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Very nice work...must be rewarding to have it come out so nice!
JP
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I know its spelled Norman Luxury Yacht, but its pronounced Throat Wobbler Mangrove!
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JoshO
Part of things
Posts: 337
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Aug 28, 2018 16:28:37 GMT
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Thread resurrection, you still got this mate? Looks smart as! Love it
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