Projekt 82 CL-D G40

[sjampoo]

Here's a little summary on my most-time-consuming project of the last months..

I bought this polo when I saw an add on our registers website ( www.polo86c.nl ). It's a 'real' 86c as it is a 1982 model with chassisnumberWVWZZZ86ZCW058310. I fancied the car because it has the 'one year only' flat rearview mirrors, and it looked like quite a undamaged car, in 'diamont-silver': It could be a panel-donor for my 1981 GL (same color), and with a primer finish be a replacement for my daily beater.

Here's how it looked like in the add:

http://www.polo86c.nl/iB_html/uploads/post-12-78282-DSC02007klein_original.jpg

http://www.polo86c.nl/iB_html/uploads/post-12-78306-DSC02009klein_original.jpg

http://www.polo86c.nl/iB_html/uploads/post-12-78321-DSC02011klein_original.jpg

Quite all-right. If does feature some minor dents on the front right wing and the bootlid (as visible on the second picture), but it did look ok overall. Since I do have a daytime job, I visited the seller and inspected the car.. in the evening. I'll tell you this: in the moonlight, every car looks good!

No seriously: The dent on the bootlid looked far worse then I expected, the 'top' of the car has been resprayed (professionally, but with some color-difference): Probably the result of serious hail. But overall it still is quite ok, not to say excellent for a 24 year old car.

First landmark was to get the car running PROPERLY. The ignition wasn't all to happy to rev above 3500 rpm,. accelerator-pump was completly off/non functional and the waterpump was leaking water... So we started to do some cosmetic surgery:

Bfore / After:
http://www.polo86c.nl/iB_html/uploads/post-12-79585-tankje.jpg

And finally I fitted a bigger unit :)
http://www.polo86c.nl/iB_html/uploads/post-12-79672-motor.jpg

I've even sourced a 8 liter unit, but that'll come in later (if there's still room).

The ignition was fixed/swapped and the accelerator-pump has been adjusted to offcourse, but that doesn't look good in pictures

After this, I dug out an NOS rear hatch, since my damage-repair-skills did turn the original hatch from 'slightly-dented-not-to-bad' to 'cracked-paint-total-loss' in just 2 minutes..
Some loony did paint this hatch in diamont silver
n black trim, Opel/Vauxhall Corsa/Nova GSI style, but he crashed the rest off the car before he could fit it.

http://www.polo86c.nl/iB_html/uploads/post-12-84518-mindergeslaagd.jpg
Looks quite awfull to me, with the black rearclusters and the missing mudflap. The other remaining mudflap went, the original lights came back in, and it isn't all that noxious.

Then, to get it MOT'ed the usual repairs followed: battery-floor, licenceplate lights, and some other minor things. Turned out the front brakes needed some inspection, and since time was a factor I had them fixed..

Some time went by. Did get the engine to run a bit more economical: it was doing 1 liter per 10 km (10liter every 100km's), and although it did consume like a porsche, it didn't feel drive one..

Summer arrived, and I finally sourced tyres to fit these NOS Centra Pepperpots: 175/50 R14 Pirelli P6000 on 6J-R14-ET48.

http://www.volksforum.com/albums/files/3/9/DSC00011.JPG

http://www.volksforum.com/albums/files/3/9/DSC00009.JPG

http://www.volksforum.com/albums/files/3/9/DSC00010.JPG

As you can see, it's not lowerred at the front.. but it's hanging to the back.. Did I only lower the rear? Nope. It's allready having it's new engine lying around in the back..

Because my daily needs to go, and I did drive that daily at 16 km / liter (6,25 liter/100) I wanted to get something REALLY economical..

I first planned to swap the petrol engine in my daily to a diesel, but the high-diesel-tax-rate killed that plan. This car is all-most 25 years off age, which means it will turn tax-free in the netherlands, it would be economical x 2.

Here's one diesel engine:
http://www.polo86c.nl/iB_html/uploads/post-9-63830-IMG_5361s.JPG

and here's another:
http://www.polo86c.nl/iB_html/uploads/post-9-14352-markok.jpg
(Thanks Mark for stating it's all 'OKAY' but the engine wasn't anyways)

To get the diesel engine conversion through the conversion-test of the 'RDW', I need to get a Polo 2 Diesel engine in (engine code MN, 1300cc, 40BHP), but the later Polo 2f diesel engine is way more powerfull: code 1W, 1400 cc with 43 BHP...
Plan: swap to MN 30BHP, get it lincenced, that swap to 1W 43BHP.
The original petrol engine is a 1300cc HH block with 60BHP: The chassis will hold those enormous amounts of 43BHP easily, but to get it licenced 'the cheap way' I need to do it like this. Swapping it directly to a 1W engine would make the conversion test about 10 times as expensive.


Here's the first test, to see whatever is wrong with the 1.3 liter diesel engine (which came out of a breaker-car, which was being scraped since the engine died)
http://www.polo86c.nl/iB_html/uploads/post-12-66285-diesel.jpg

It turned out it was running on only 2 cilinders. Here's why:
http://www.polo86c.nl/iB_html/uploads/post-12-61487-2poten.jpg

And somewhere in it's horrible life the timing of the camshaft was off to:
http://www.polo86c.nl/iB_html/uploads/post-12-61766-klep.jpg

Needless to say we fixed the headgasket, and got it up running on 3 and 4 cilinders: cilinder 1 is still a bit awkward.. maybe some injector problems?

Before I will fit the engine, the suspension needs to be updated: I fitted a 2f GT rear axle: 6mm thick and with stabilizer,. and i swapped the complete front to Diesel / 5 gear specs :
http://www.polo86c.nl/iB_html/uploads/post-12-32762-weerwatverder.jpg
You can see the soundproofing that's allready waiting for the diesel to arrive.

When the speedo died (or better: the tacho did), i swapped to a mile-speedo, so even with the diesel engine in, I'll be using the whole scale (I hope).

http://www.polo86c.nl/iB_html/uploads/post-12-79516-maagd.jpg

Yesterday, we finally swapped the engine: Here's me checking out the enginebay from an unusual perspective:

http://www.polo86c.nl/iB_html/uploads/post-12-36310-alternatieveSjon.jpg

And this is me, still smiling...

http://www.polo86c.nl/iB_html/uploads/post-12-36511-sjon.jpg

It turned out things where more complicated than we expected, so somewhere last night (or this morning) I finally drove home with an alternator giving 16 volts off power, and a speedo going to 70 miles TOPS..

Thanx to Marcel86c for all the help, work and coffee!

More to come, later on..

[Berserker]

Jolly good english mate

http://www.cartersteapots.com/teapotshop/englishlifegentleman.jpg

fancy a cup of tea?

[sjampoo]

Just to boost activity in the international polo section abit..

Nothing wrong with that is there?

[Berserker]

Just to boost activity in the international polo section abit..

Nothing wrong with that is there?

of course not, :confused:

just complementing on your english :D

[Stijn]

Cool project, I know all about the strange ways of RDW... But still a good way to get around the rules, although it is a lot of work :)


Nest step: 1W turbo?

[PerL]

Just to boost activity in the international polo section abit..

Nothing wrong with that is there?

Absolutely not, this place is too quiet, so anything is welcome.

The car looks to be in very decent condition, given its age. Do you dutch guys have taxes based on what kind of engine is in the car? No such thing here, only a flat-rate passenger car tax.

Oh, and please explain, why so much more difficult to just go for the newer engine directly? I mean, the volume (cc) is barely bigger, the hp also, and your still down almost 20 hp from your original engine! I simply dont get it!

[Mark1]

Car taxes overhere are based on weight and fueltype.

So converting from gasoline/petrol to diesel means getting the registration changed.
But this can only be done cheaply ( this a low budget project afterall..) if you place an engine that was
originally available in the early Polo 2's ( the MN engine ).

[sjampoo]

Exactemundo..

If you fit another engine, which was originally sold as such in your model (but in another car), it's in there 'database' of 'known-good-setups'. So when I fit a MN engine the type will change from: 867 131 (Polo CL, 4 speed tranny, HH engine (60 horses petrol) to 867 194 (Polo CL, 5 speed tranny, MN engine (40 horses diesel).

There is no 'type' which states 'Polo CL, 5 speed tranny, 1W engine (43 horses diesel), so that would force a 'complete' testing: road-track testing, sound tests, etc etc: very expensive, for 3 horses moren.

IF it allready has got the 40 horses MN engine on the licence/registration, I can easily pop-in an 1W engine since there aint no big changes in horses or fuel. the usual MOT-guys won't notice, and no-one will care.

--
@ Stijn: Since I'm allready depressed on the power-output,. the 1.4 liter engine will swap straight in if the MOT-test goes ok next thursday,.. but in the end, that won't do the trick: Either I'll fit a G40 charger (expensive but original :) ) or build myself the 1.6 diesel block out of petrol+diesel blocks (data not available: probably a project to fail), or it'll get a turbo, or a combination of all these..

[sjampoo]

BTW: drove it today.. (couldn't resist), but it does fume abit....

If it's warm, it does get better, but there's an oily cloud behind me... :eek:

[PerL]

There is no 'type' which states 'Polo CL, 5 speed tranny, 1W engine (43 horses diesel), so that would force a 'complete' testing: road-track testing, sound tests, etc etc: very expensive, for 3 horses moren.

IF it allready has got the 40 horses MN engine on the licence/registration, I can easily pop-in an 1W engine since there aint no big changes in horses or fuel. the usual MOT-guys won't notice, and no-one will care.

Ok, then I understand. Luckily not that difficult here in Norway.

[Stijn]

BTW: drove it today.. (couldn't resist), but it does fume abit....

If it's warm, it does get better, but there's an oily cloud behind me... :eek:

blue or black?

[sjampoo]

Blue,.. but it disappears when the engine gets warm/hot..



More news on the front:

Been to the RDW today,.. it's tested AND approved!
Emission-test: K-value 1.0 (2.5 allowed).

Wasn't that simple though: the car's of 1982, and the approval-specs are all dated 1987 and later.. But I could convince Mrs Bakker that it was all okay and stuff :)
His wife drives a 1983 Polo Classic, so he could appreciate my work on the car :)

[sjampoo]

What did the mailman drag in to day? The paperwork! Wow! that's fastXL! Thumbsup for Hajee and his collegues
Tuesday -> Tested and approved
Thursday -> All paperwork has been done, and my freshly printed licencee has arrived in the mail.

Check the online specs: One capture of wednesday, and one of today:

http://www.polo86c.nl/iB_html/uploads/post-12-95043-HN_41_FN_Benzine.jpg

http://www.polo86c.nl/iB_html/uploads/post-12-60833-HN_41_FN_Diesel.jpg

[PerL]

Aantal Zitplaatsen 0 - isnt that a bit unpractical? :D

[Gallagher]

the dutch are obviously small people ;)

[sjampoo]

Just came back from the int. polo meeting in Denmark.

It did run well (93 mph max), but it's burning oil aswell.. Bigtime! 1 liter, every 300 km.


Didn't stop Marjolijn from taking some rolling shots:

http://www.polo86c.nl/iB_html/uploads/post-26-30422-P1010005.JPG

http://www.polo86c.nl/iB_html/uploads/post-26-30406-P1010001.JPG

Since it's running on oil (sort off), I'll change to the other (1.4) engine a bit quicker..

[sjampoo]

Extremely small update:

- 1.3 liter engine is still in (vacation, no time, etc etc).
- It's still running, but takes up to 1 liter of oil per 250 km's.
- Installed a manometer to measure the pressure at the fuel-line.

pressure running diesel is about -0,2 bar
pressure on pure vegetable oil is about -0,8 bar. WAY to low.

[sjampoo]

Update

No matter how long I abuse the little 1.3 liter diesel engine, it keeps on running.. Yes, it even passed the MOT (APK) last month which includes a particle test..


Since my last update i've upgraded the fuel-lines to ID 10mm spec.. Some may call it 'garden hose spec'...

Oh well,. it is a hosepipe. Pressure on vegy oil: -0,2 bar max :)
http://www.polo86c.nl/iB_html/uploads/post-12-53450-slang_door_firewall.jpg

It runs through the interiour to keep things nice warm and cosy. In the engine bay the oil flows through a heat-exchangers, electrical heater, diesel filter and feeds the engine at about 80 degrees celcius.

Top view:
http://www.polo86c.nl/iB_html/uploads/post-12-07863-pompje.jpg

The extra glass filter has only been there temporarily, just to keep large particles away, and it turned out to be one hell of an leaky **** causing all sorts of unexpected problems.

The fuellines in the end got some isolating stuff wrapped around and all works fine without air-leaks.

As it's kind-off a daily beater, things do need maintenance. Things tend to break.. like shock absorbers. And as it is a beater, on a tight budget.. I had to swap the complete suspension to -60mm.. as that's what I got laying around.. horrific.

http://www.polo86c.nl/iB_html/uploads/post-12-50353-lowered.JPG

Doesn't look that low, but trust me: it's satisfactory to me :) The rearwheels are allmost completely within the arches:

http://www.polo86c.nl/iB_html/uploads/post-12-11473-laagzat.jpg

Will go nicely with the 14" summer rimms.

I purchased a G40 charger, and it's at 'Arno' to get the full revision treatment: Seals, bearings, the works. (no pics, it will get sandblasted :) )

In the meantime, been making some room, and fitted the famous G40 metal thingy to create room for the charger and it's hoses:
http://www.polo86c.nl/iB_html/uploads/post-12-01730-blikje_manenschijn.jpg

The enginemount fitting the 1.4 diesel engine arrived to day:
http://www.polo86c.nl/iB_html/uploads/post-12-02282-steun.jpg
It's the three hole version, which fits the older engines:
http://www.polo86c.nl/iB_html/uploads/post-12-42483-pastdat.jpg




With the engine mount delivered, and the complete G40 spec exhaust laying around I hope the swap to the 1.4 liter engine within a few months :)

[RubenD]

Looking good, hope you can get it to run properly with the G40!

P.S. I suppose you mean: tight?

on a thing budget..

[Tjaap]

tight?

[René]

A G-Lader on a diesel? that`s really cool! :cool:

[Stijn]

Ah congratulations, it turned 25 last month!

[sjampoo]

Looking good, hope you can get it to run properly with the G40!

P.S. I suppose you mean: tight?

Who? What? Where?

Oh yeah, well [filling in lame excuses:] it was kinda late last night,.


Anyway, I forgot to mention it: I also sourced a original Polo 2 GT G40 intercooler, and got some other stuff for the Volkswagen 'Classics' department in Germany to: 'Windleiter fuer ladeluftkuhler' and the part from the 'Schlosstraeger' came from those guys in Wolfburg... And 4 brand new 'vorstrahl' diesel injectors to. They are waiting to be installed, after I had the properly adjusted to 245 bar opening pressure.. Man do they 'crack' on opening! That's the con,.. the big pro on this kind of level of 'DöD' is the even the thickes lard will squeeze out in a nice straight cone of 'ready to ignite' fuel. That, and the Bosch Duratherm Chromium glow plugs will make it possible for a cold start on straight vegetable oil.

[PerL]

A G-Lader on a diesel? that`s really cool! :cool:

X2! :thumbup:

I wonder if that would work with a G60 and a 1.6/1.9 diesel engine? :confused: Methinks the injection pump and G60 would interfere...

[Tjaap]

any updates pookie?

[sjampoo]

Nah,. Did do a wheel toss last night:


http://www.youtube.com/v/85SDCBw1bHU

The Diesel is now back on it's own summer wheels, the HoekHoek (formally known as ToekToek) finally got it's white rimms :)

(Centra Pepperpots, NOS, 14x6 et38, with P6000 175/50 r14 )

[sjampoo]

fixed link :)

(Music: Morphine - Sharks )

[sjampoo]

small update:

I just can't kill the 1300cc diesel engine I put in last year.. no matter how much I abuse the little basterd; It keeps on going.

It made me feel heroic, and I could not resist to take the car for a spin ( or 3 to be exact ) on the legendary Nurburgring Nordschleife..

http://www.volksforum.com/albums/files/3/9/2984090570087850233gbxqnY_fs.jpg

Meanwhile,. the 2 or maybe even 300.000 km's only made it take about 2 liters of oil..

The abscence of any power at all forced me to take some measures on my timing skale (which doesn't exist)

Working on an inlet.

First attempt:
http://www.polo86c.nl/iB_html/uploads/post-12-35727-sleutelen3.jpg

It turns out there might be appropriate space between the firewall and diesel-pump anyway....

From the top looking down, it sure looks like it might fit, but in real-life it's all quite crowded. Bonnet squezes everything down and does lock, but with any movements of the engine, it probably won't take long to have friction dismantle the lot...
http://www.polo86c.nl/iB_html/uploads/post-12-98643-achter_boven_langs.JPG

Some space can be acquired by modifying the brake-servo's position masterbrake
still in doubt if I need a pressure-regulating system:

Standard fit on empty-body-shell:
http://www.polo86c.nl/iB_html/uploads/post-12-98724-rembekrachtiger_standaard.JPG

Modded fit (top down)
http://www.polo86c.nl/iB_html/uploads/post-12-98773-rembekrachtiger_met_verlagingsset.JPG

But since I will fit a newer model servo, including a shorter masterbrakecilinder and small reservoir, It might be obsolete to mod the mount anyway..

I still haven't figured out if I need a pressure regulating system.. Will I need a boost-control-thingy? Will it idle under pressure? Since Google only goes 'Wisssssh" and 'Woooosh" (2fast-2furious kids) when I search for a decent, working blow-off thing, of regulation.. and there's only crap available for diesel engines (turbo charged, no mechanical compressors found yet) :dunno:

We'll see.

[Tjaap]

cool, "where no man has gone before".............

[Stijn]

"To boldly go..."

[sjampoo]

WARNING: Crappy phone pics up ahead

had some welding done yesterday:
http://www.polo86c.nl/iB_html/uploads/post-12-94967-gloeiendediesel.JPG

Test fit on a external engine (nevermind the dutch). With the pump on maximum pre-injection, there's room, but only just. Nothing serious, since the fitting plate has some room for adjustments build in. The (gas?)lever is freely manouvreble.

Test fitment in the car:
http://www.polo86c.nl/iB_html/uploads/post-12-94486-inlaat.JPG

I hoped I wouldn't have to adjust any original Polo 2 G40 intercooler hoses, but it just won't fit.. where't that chainsaw? :)

Sample pic: standard Polo 2 GT G40 (petrol):
http://img112.imageshack.us/img112/7260/img3299qv3.jpg

As you can see: the piping with 'Ladeluft gekült' on it won't fit,. so, to go with Dexter: "Let's Modify!"



Oh and I've been working on the engine aswell,. to make it only a little more 'Veggy-power-capable) new (brand new) injectors, slightly adjusted to 245 bar opening pressure :grin: , brand new glowplugs, Bosch Duratherm Chromium,.
http://www.polo86c.nl/iB_html/uploads/post-12-95414-plug_n_injector.JPG

Note: the glowplugs are just a few mm's longer.. but now there just off-center from where the diesel injector will spit it's veggy-juice:

http://www.polo86c.nl/iB_html/uploads/post-12-96952-glowinthedark.JPG

With the mods it should be capable of doing a cold start on 100% vegetable oil.. in mid winter :) (and with the electric pre-heater, heat-exchanger, huge fuellines and isolation it'll be sweden capable :) )

[sjampoo]

It's been a month now since my last posting, so time for an update..

I allready bought myself a G40 charger (Polo 2f, later model).. and have been sourcing specific Polo 2 G40 stuff since then. A Polo 2 G-charger would offcourse be the cherry on top, but I since there's a serious chance the charger will blow, and I'm not willing to destroy a 'typ 1 charger' for that purpose.

Anyways:

G-charger exit arch: Not the differences between radius and thus ' height'

http://www.polo86c.nl/iB_html/uploads/post-12-85034-diepte.JPG

Not only is the 'off-set' different from the polo 2f charger-exhaust, it's got a different angle to:

http://www.polo86c.nl/iB_html/uploads/post-12-85081-hoek_lengte.jpg

On the good-old Polo 2, the intercooler is fitted allmost directly underneath the charger, since there's no real space in the car front section. With the longer, much rounder front on the 2f, Volkswagen decided they could make things much easier for there mechanics to change stuff on the ' most powerful polo', and reduce production costs abit more. The Polo 2 G40 was quite labour intensive to build. I've read somewhere in the past that even Karmann was involded in cutting up the front section and installing the G-charger...

Anyways:I bought my charger from some guy who's doing a lysholl swap on his Polo, and the visual state of the charger was quite good. I had ' Arno ' do a checkup, and he did advice to do a complete rebuild. Picked it up last month:

http://www.polo86c.nl/iB_html/uploads/post-12-00787-AZM5172007.JPG It's the 51'st charger he has rebuild, and included a full 'glass-perl-blast-job', all new wearing parts (seals, bearings) a fresh lube with kluber grease, etc etc..

http://www.polo86c.nl/iB_html/uploads/post-12-01074-klubber.JPG

He did a fine job, and I really like the way he's working: clean, exact and patient.

I've been collecting polo 2 G40 hoses and piping, but the pressure-tube directly from charger to intercooler isn't easy to get a hold off: the Polo 2f version is much longer and weaker (tends to tear), the Polo 2 version is enforced, and secondhand allmost as expensive as a brandnew one from vw-classicparts (volkswagen-museum-parts-supplier).

http://www.polo86c.nl/iB_html/uploads/post-12-65227-whatthecatdraggedin.jpg

(badging is obligatory)

With all these components, and a assortment of exhaustpipe arches,.. I think I've got the pressure side collected:

http://www.polo86c.nl/iB_html/uploads/post-12-85738-compleet.JPG

First test-fitting on the engine: no problems at all:


http://www.volksforum.com/albums/files/3/9/10072007285.jpeg

But,.. As you might notice, (and what I've stated before) there's about no room for the tubing to get from intercooler to inlet..

http://www.polo86c.nl/iB_html/uploads/post-12-17595-before.jpg

about this much:

http://www.polo86c.nl/iB_html/uploads/post-12-18013-weinigruimte.jpg

To get ' a little extra room ' I've changed from old to newer type masterbrake cilinder:
which not only has a less spacious boosterdrum, but a shorter cilinder and reservoir:
http://www.polo86c.nl/iB_html/uploads/post-12-17910-remhoofdcilinders.jpg

See:
http://www.polo86c.nl/iB_html/uploads/post-12-18272-ruimte.JPG

With a little help from our friend from ' bayern ' ( 90 degree angle tubing from A BMW 5-series diesel ) the top section is fixed:

http://www.polo86c.nl/iB_html/uploads/post-12-18574-fits.jpg..

The sub-section is mainly the intercooler part. Cut away some sheet-metal:

http://www.polo86c.nl/iB_html/uploads/post-12-45526-sneak.JPG

to get this result, completely in ' stock Polo 2 GT G40 Cup look '

http://www.polo86c.nl/iB_html/uploads/post-12-45674-frontgaten.JPG

bought a brand new radiator,. since the large Dieselrad will interfere with the charger

http://www.polo86c.nl/iB_html/uploads/post-12-64876-rad.jpg

modded the front-travese section:

original:

http://www.polo86c.nl/iB_html/uploads/post-12-26926-maagdelijk.jpg

convinced some metal to change shape:

http://www.polo86c.nl/iB_html/uploads/post-12-27069-bult_bol_naar_hol.jpg

Pliers and a blowtorch made it look like mid-evil:

http://www.polo86c.nl/iB_html/uploads/post-12-27157-inslijpen_branden.jpg

fresh sheetmetal, a A smear of bondo and a large-hole-cutting-thingy-on-a-drill made this possible:

http://www.polo86c.nl/iB_html/uploads/post-12-27244-gatgezaagd.jpg

After a respray, no-one will notice the difference between this and a original Polo 2 G40 :)

http://www.polo86c.nl/iB_html/uploads/post-12-27351-klaar.jpg

Keep you posted!

[Tjaap]

the framerails look perfectly stock.. great job, and love the cut-outs on the lower lip.

[ruben]

Nice job Sjampoo!

i contacted you before because I had similar plans. But no way I could have done this myself--> Respect!
Will you change anything on the diesel pump? Since your engine is boosted by now it could use an LDA; or isn't there any space left cause of the ic piping?

Grtz,

Ruben

[sjampoo]

Nice job Sjampoo!

i contacted you before because I had similar plans. But no way I could have done this myself--> Respect!
Will you change anything on the diesel pump? Since your engine is boosted by now it could use an LDA; or isn't there any space left cause of the ic piping?

Grtz,

Ruben


Maybe it's the wrong way around, but I'm doing it the ' trail-and-error ': For starters I'll only enrich the pump (since the charger will blow from low to high revs: even on idle speed there's ' pressure ').. But if it all fails.. I'll be paying DA-brt (or what's his name) a visit to get my pump fixed/tuned/lda'ed (he doesn't know yet)

By the way: About ALL metal work has been done by Marcel86c, so mainly all credit goes to him: I'm one the guy getting his hands dirty with oil/paint/crap doing nothing really :)

[Marcski]

awesome work.. can't wait to see it done

[PerL]

G40 diesel... Simply awesome. Why didnt VW think of this themselves? Any guess what hp this thing will make?

[Stijn]

Very nice! Looking forward to seeing this completed. Still a great idea, always wanted to build a G60 diesel, but you beat me to it!

[Sjon]

.

[sjampoo]

They already did: Eko-polo (http://www.polo86c.nl/cgi-bin/forum/ikonboard.cgi?;act=ST;f=4;t=260;hl=diesel+g40)
But never in production......

With LESS than 3 liters consumption per 100km

But I'll be satisfied with less then the ' 5.8 ' that it's currently doing:


http://images.spritmonitor.de/128339_5.png (http://www.spritmonitor.de/en/detail/128339.html)

[Sjon]

.

[sjampoo]

Let's double the power, and the mileage :)

[sjampoo]

Teaser:

http://www.polo86c.nl/iB_html/uploads/post-12-54605-sideview.jpg


Notice anything new?

[sjampoo]

It's been awhile again, and not to many things done, no major updates to mention..

If you look closely to the picture above, you might have spotted the front spoiler. Yes. I did get a hold off a genuine Polo 2 G40 front spoiler!

http://www.polo86c.nl/iB_html/uploads/post-12-54679-top.jpg


http://www.polo86c.nl/iB_html/uploads/post-12-78738-DSC00188__Large_.JPG
http://www.polo86c.nl/iB_html/uploads/post-12-78798-DSC00189__Large_.JPG

I had to get used to it's new look, cuz there's lot of black at the nose, but after I while I got used to it.. Yeah, I know: :screwy:

Have been to the nurburgring again for a nice weekend of fast-cars and bbq.. and I couldn't resist to torture the current engine some more. Luckily for the 1.3 the track was still damp and I didn't have that much grip.. Still had some fun, but not as much as an unexperienced can have on a dry track

http://www.polo86c.nl/iB_html/uploads/post-26-65531-09092007386__Small_.jpg

We've been there at the weekend following the Scuderia Drivers training, so at Brunnchen the viewers-parking changed from a muddy-surface into a Porsche Dealership within 50 minutes..

http://www.polo86c.nl/~fileserver/Michiel-110907/P1010886.JPG

Really nice weekend, and astonishing that after only a day or two you completely forget that a porsche 911 GT3RS isn't a common car in 'normal life'. At the Nurburgring there only sold by the dozen..

talking about dozen: fuel my fire :)

http://www.polo86c.nl/~fileserver/Michiel-110907/P1010868.JPG

Anyway: back on project:

Had some trouble getting the belts in position, and timing set.

http://www.polo86c.nl/iB_html/uploads/post-12-10473-riemen_zicht2.jpg

After some trial fittings I had to mod and order:
The diesel alternator is mounted on a M12 bolt, a G40 only on a M10, with a spacer. Modded the alternator to M10 (hammered in an alu-tube :) The V-belt tensioner of a diesel/petrol differs from the G40 setup: the charger actually works as tensioner. So on the pic above you still see the tension-bracket, but I had to order a G40-spec mount, since the alternator didn't line up straight: different off-set? Nope. In the end I modded the alternator again: offset is of the complete alternator is different, so I had to slice off some aluminum with a grinder.

The timing of a Diesel is quite important (I guess), but normally there's only this lumpy mark on the flywheel... How this can be used to time anything without special tools is a complete mistery to me.
Since the double-v-pulley has a timing mark on it, I decided I'd time it on the petrol way. Ordered a timing wedge, but that didn't line up at all. The mechanical-rocker-follower-head has different markings, some knowledge I didn't have before.
The lower belt cover decided it didn't fit anyway: the markings on it interfere with the double-v-belts:

http://www.polo86c.nl/iB_html/uploads/post-12-10595-zundungs_markierung.jpg

So, yet another piece of specific G40 parts ordered: lower G40 timingbelt cover. It has the timing-marks build in an a slightly different spot; Fits perfectly, and lines up quite well! :)

In the meantime the fueltank fillerneck decided to start leaking. While my budget is going rock-bottom, ordered a new fuel tank, which is yet to be mounted. Running my 'home-made-race-tank' for the time being. Will be putting some special paint on the fillerneck, all in style of the öko-polo / 3L :D

More recently visited the "Volksforum Paintless Dent Repair Day" and got some parking dent removed: Have been to the supermarket a bit to often lately I guess? The doors, right front fender and left rear panel are now back in shape! Thanks to the wizards of 'X-pair' in Naaldwijk (NL).

http://passat.sjig.nl/Uitdeukdag/Volksforum-Uitdeukdag%20(1).jpg

Thanks so far to:
Marcel Statz (for every weld, grind, the workspace and coffee)
Mark Pruim (my canadian-connection for the special pictures)
Dirk and the X-pair team (for the paintless dent repairs)
Michiel Ros (for the nurburgring pics)
Leontine ( for her patience )
and my volkswagen dealership for there time and 'no-questions-asked' when I'm ordering another mixture of parts :)

keep u posted, but don't expect the engine running before the end of this year...

[Tjaap]

it looks good buddy, i was really impressed!

[Gallagher]

after what I understand, you are building a 640 diesel :) Although it has been done befre, this is innovation my friend :)

good luck and looking forward to see some hp measurements..

[sjampoo]

640? No,. G40 :)

If it has been before, please let me know: I could use loads of info.. (but I haven't found anything (not even clue's) on this being build before).

hp measurements? Nah.. TORQUE output!

[Gallagher]

I know it has been done before.. Had an image on my old computer of a diesel g40 engine... rare, but doable :) hp or torque: same shit, different wrapping :)

[sjampoo]

This one Gallagher?

http://home.arcor.de/poloheinz/%25d6ko-Polo-2%2520800x1111crop.jpg

This has been an official EA (entwicklungsAuftrag) from VW in the eighties.

If not,. get your old computer running again, and show us pics please :)

http://www.nndb.com/people/711/000022645/gallagher-maddest.jpg

[Gallagher]

There is not any hope for my old computer I am sorry to say.. I was'nt about the two cylindered vw supercharged diesel.. I am sorry.. If I had the pictures, I wuold have shown them to you..

[serge pot]

Update

With the engine mount delivered, and the complete G40 spec exhaust laying around I hope the swap to the 1.4 liter engine within a few months :)

uhuh ,few months ,iff this is what you mean with the 86c register ,i won't hold my breath ,becaus i will die :D

but how are things going ?

[sjampoo]

Things are going 'great'..

months fly-away: Didn't really get anywhere since my last update, I only sourced more and more parts.. and got the IC hosing done.

http://www.polo86c.nl/smf/index.php?action=dlattach;topic=3788.0;attach=8643;image

Don't get alarmed by the big green valve-cover: It's just the color I will use to 'stipulate' the lines in the G40 valve-cover: it's eco-thingy-character. And I've done the fuel-tank in the same color.. :screwy:

Fuel-tank? Yes, it was rotten-away, so needed to change it. It was leaking veggy-oil, diesel and worse: it was desolving tectyl of the tank, onto the pavement: very ugly black stains, where ever I went. Fuel-economics aren't that good either..

New tank, in 'eco-friendly, hell, where are my shades?, yellow-green'
http://www.polo86c.nl/smf/index.php?action=dlattach;topic=3788.0;attach=1722;image

Since I'm getting married in January, I didn't find the time to do that much though: I'm trying to get my Polo 1 to look somewhat.. ehmz..'photoworthy' Pics of that car (and day) i'll be posting after our honeymoon :)

Anyway: Oil-feed and return hoses for the charger have arrived, the center console which will house the various dials and switches to, breather-hosing of the sump is allmost complete: I only need time to get the engine to run for a test-cycle...

And the MOT/TUV/APK will be in March 2008 again: I don't know if the current (still the good old stinking 1300) will make it through ones more.. otherwise I'll have to hurry,. which isn't in my nature..


keep u posted.

[Stijn]

You're getting married too??

Good to see some work done on the crazy veggie Pollo. Intercooler tubing looks good. Not sure about the green paint though :)

[serge pot]

:screwy: green paint :screwy:

the rest :thumbup:

[sjampoo]

You're getting married too??



Race you to the altar! :)

[Stijn]

LOL, you got me beat already

[serge pot]

did winn 9-9-99

[Tjaap]

09-09-1999? damn, Wendy is making sure you won't forget the date

[sjampoo]

* finally the 1.3 diesel died on me on *

http://www.polo86c.nl/smf/index.php?action=dlattach;topic=3788.0;attach=12547;image
This give the GDi40 project a bit of a boost, and might be running within a few weeks from now.

Inlet manifold further tweaked, only 16hrs after engine failure..

http://www.polo86c.nl/smf/index.php?action=dlattach;topic=3788.0;attach=12567;image

oil lines to and from G-40 charger are fixed, engine pre-heater installed, and the missing-parts-o-meter is going down steady..

Wot? no room?
http://www.polo86c.nl/smf/index.php?action=dlattach;topic=3788.0;attach=11972;image
But only just;
http://www.polo86c.nl/smf/index.php?action=dlattach;topic=3788.0;attach=11974;image
(oil filter is mildly in the way)

Did do a 'drive-train' upgrade in between, with G40 trackcontrol arms, which do have unibals instead of big rubber bushes. They can be demolished, so a little warning sign for the MOT guy is in place:
http://www.polo86c.nl/smf/index.php?action=dlattach;topic=3788.0;attach=11680;image

Sorry for not being around that much, but I did get married, and got all running (that's 4!) polo's through the MOT in the last 3 months,... all with minor to major work.

[Marcski]

what does the label say? I can only read the first 2 words and NOT :D

[sjampoo]

Don't even think of coming near with a tyre iron


Problem is: there are rubber-dustcaps on them, only penny's worth, but there not for sale (haven't sourced them anyway).. So: busted-dustcap equals new trackcontrolarm @ about 100 euro's a piece.

[sjampoo]

Just to let you know,.. F*ck you all: It's running! And I'm SO freak'n happy . Didn't take the time for pictures or video. Will have to get thing adjusted soon though: i draw a think, black line on the tarmac: Smokin, so WAY to rich. But in nowhere near anything like a normal diesel

Will keep you posted!

http://www.polo86c.nl/smf/index.php?action=dlattach;topic=3788.0;attach=12738;image

http://www.polo86c.nl/smf/index.php?action=dlattach;topic=3788.0;attach=12743;image

[Viperwin]

I like it. A lot.

You can fit the biggest engine you can find, but it will never give the same satisfaction as this must be giving you.

[Erik]

Damn nice project Sjampoo and at last the satisfaction of a running engine. :thumbup:

[PerL]

Cool! Very cool!

[sjampoo]

Will be fixing the exhaust (which is hammering against the floor at idle) tonight, and hopefully install important stuff like gauges (oil pressure, oil temp and charger pressure).

Will take some pics of the only halfway finished underbonnet area.

[knarfmk1]

Good progress! Curious what hp and Nm it will do once it's adjusted well enough!

[Stijn]

COOL!!!!

I need to start building a G60D now :)

[sjampoo]

http://www.polo86c.nl/smf/index.php?action=dlattach;topic=3788.0;attach=12954;image

Did I say I was a Pic-Whore allready?

[sjampoo]

I didn't?

http://www.polo86c.nl/smf/index.php?action=dlattach;topic=3788.0;attach=12944;image

[sjampoo]

Must have said so before....

http://www.polo86c.nl/smf/index.php?action=dlattach;topic=3788.0;attach=12949;image

[sjampoo]

http://nl.youtube.com/watch?v=vKB-I3fmzc8

Sound is very poor, but you'll hear some of the rattle..

The movie is actually to show the resonating engine. If you look at the movie you'll notice the gas-lever and tubing 'swinging'.. but in real-life it's shaking like a madman.. Due to the stroboscopic effect ( # of seperate images taken per second) you only see a swing, not the shake/rattle.

[sjampoo]

(and do check out the other clips on youtube, I'm uploading another one as we speak.. )

[PerL]

Looks hot!

[Tjaap]

very impressed Sjampoo.. very impressed

[RubenD]

(and do check out the other clips on youtube, I'm uploading another one as we speak.. )
I just really love the sound of the G40. I'd like to have a drive with you in this Polo! I live in Arnhem so that can be arranged, can't it! ;)?

[sjampoo]

http://nl.youtube.com/watch?v=GpRaGvgyqw0 ( here you can vaguely hear the supercharger humming abit (when I touch throttle)

[Marcski]

absolutely awesome... (and a valid excuse for not posting so much ;))

[Pedaalemmer]

I love it!

[Richard]

http://nl.youtube.com/watch?v=ssjaX87fyus&feature=related

wheels spinning in a diesel polo..:D

[sjampoo]

:)

And that's on a cam-phone.. :)

Just got back from a wonderfull, warm day @ RetroMania,.. AND got past the 1000 km 'running' in. It's now ready to be 'tuned', and used. Did have some temp. problems though: Can't run it at 100km/h for a long time, or oil temp raises to 130+ 0C. So in need of an oil-cooler. Thinking of an EGT aswell, since I do just love how smooth it runs (exept for idle).

Very nice to just have the feel of that pile of torque left as reserve under my rightfoot, and knowing it will only be getting more out of it.

And btw: stunning to see that the number of hits on 'G40 + Diesel' on google suddenly raising...
http://forums.tdiclub.com/showthread.php?p=2137043
http://forums.vwvortex.com/zerothread?id=3829579
http://www.vwdiesel.net/phpBB/viewtopic.php?t=8398&start=0&postdays=0&postorder=asc&highlight=supercharger
http://en.wikipedia.org/wiki/Volkswagen_Polo_Mk_II

Wonder what mileage is in it to. :)

[PerL]

Any idea how many hp it has? You should do a test with a G-Tech.

[sjampoo]

Any idea how many hp it has? You should do a test with a G-Tech.

Since I've been 'running-in' the G-charger, I only recently started to put the pedal to the metal..
I really haven't got a clue yet, and the 'feel' is so different from any (non)-turbo-petrol/diesel car, I've driven, so I can't really tell what it compares with.

Stating this doesn't mean it's a really unique feel; I just don't know what it feels like since I haven't driven that many different (powerfull) cars :)

I did stick to the boot of a 1.3 liter (petrol) polo on motorcycle carbs, where the owner (Serge) thinks it should produce about 70-75 BHP... The Audi A4 20v 1.8 (Marcel86c) behind us couldn't keep up..

2 major things need to be solved though:
- Oil temp is going up at any speed above 100 km/h. It stays in the 'okay' area ( 110 degrees C) as long as I don't go over 100 km/h (for more than about 2 minutes).
It goes over 120 / 130 degrees as soon as I keep it above 105 km/h for longer
then 2 minutes. Have got a big oilcooler, which I will setup in front of the radiator. Brackets have to be made though, and a termostat/tubing is missing to.

- fuel: it's still on the very lean side. Will have to modify the fuelpump, but I've been calculating what pouly I can use to: running a 75mm stock pouly on the charger now, but when fitting a 65mm (don't panic) pouly, it will run just as fast as a stock-petrol G-40; A diesel engine will only do 5500 rpm max, where the petrol version goes up to a whopping 6300 rpm (to 6500 rpm) until the revlimiter kicks in.
It's now doing 0.5 bar at idle, 0.6(to 0.7) at about 2000+ rpm. When I fit a pouly to spin it at normal speeds, it might even go up abit... Not dramatically I guess ( I read somewhere a G40 will only produce about 1 bar as a absolute max. ) Anyway: there will only be a bigger airflow surplus... and I didn't even modify the fuelpump far enough to compensate for the switch from atmos to charged.

Minor things I did fix:
- horn :)
- pressure gauge :)
- 100% Veggiepower :)

Minor things I'm working on:
- budget for a VDO EGT gauge
- centre console to house all dials.

[RubenD]

Then you might have a look at this website for your gauge: http://www.egauges.com/eg_typeI.asp?Type=Pyrometer&Face=All&Lighting=All&Letter=All&Bezel=All&Needle=All&Diameter=All&Manf=VDO

And I suppose that the filterhousing of a DX engine wont fit on your smallblock engine? That housing does have a built in themostat.

[PerL]

Oiltemps in the 130º range shouldn't really be a problem, as long as the coolant is at a steady 85-90º. The Audis I own/owned (my present A6, my Coupe, and the '92 Cabrio I owned earlier) that had original oil temp gauges have all had the red marking in the 170-180º range.

Are oil/water heat exchangers available for the 801 engines? I know many 827 engines have these, it might be worthwile to install one in addition to the oil radiator.

[sjampoo]

nah, i've got the oil/water heat exchanger,.. but I use it in a differnt way :) to soup up the temp from the veggiefuel :)
Since I've only got room for a 1.0 radiator, I'm not fond of the idea having the oil warmup my coolant even more. Which reminds me: Get water temp gauge fixed. I still got the dash of the petrol engine in it, which has a different scale/reading then a diesel gauge. So no real clue what the water temp is about, only that it's steady a 100 km/h, and up a bit at 110+km/h ( so yes: watertemp goes up abit with rising oiltemp).

Thanx on that egauses link; any experience on ordering? Since they are in the US, and VDO is german,, I suppose it should normally be cheaper to order from germany directly.. or do they just sell the VDO gauge with there own sender unit?

[PerL]

Since I've only got room for a 1.0 radiator, I'm not fond of the idea having the oil warmup my coolant even more.

Since there is more water than oil in the engine, and the water is thermostatically controlled, the water will keep the oil cooler, not the other way 'round. The only thing is that the fan may be running more often than now.

[RubenD]

I have looked on the internet for an oilpressure sender. In the Netherlands/Germany it would sat me back like 50-60 euro. In the states somewhere around 25-30 euro.

And as you can see here: http://www.volksforum.com/albums/files/3/5/9/7/DSCN0043.small_original.jpg
It's an original VDO part.

I don't know why, but they are a lot cheaper then what I have found anywhere within Europe.

The downside, obviously, is the import tax. Arne bought 3 gauge and the needed sender @ egauges.com http://www.volksforum.com/forum/showpost.php?p=567939&postcount=189

I didn't have a good experience with them. I orderd my pressure sender, that had to look up the costs for the USPS shipment. But they just didn't replied after that. I still don't know what went wrong. The nevertheless where really quick when Arne bought some gauges.

[sjampoo]

hmm,. sound good,. I've got the Vision Black Series, and the looks satisfy me :)

From Sandtler / DutchPowerTrading.nl
Anlage zur Überprüfung
der Abgastemperatur incl.
Geber.

Ø 52 mm
12 V, Meßbereich
100°C-900°C,
Best.-Nr. 397 015 003 C
€ 288,-

egauges sets me back a little less:
0-1600F 2 1/16 °Fx10 $99.50


Part No: 310-953 Notes: 12' Kit. (Exhaust Temperature), includes gauge (310-951), sender (323-892) and wiring harness

I just only noticed they aren't really advertising with the metric-gauges ( Fahrenheit? WTF?! ),. so I'll check out what payments the accept (paypal?) and if they can deliver gauges in metric.

Thanx for your help/tip sofar!

[Gallagher]

congratulations my friend :)

[serge pot]

Giesel in Action (http://www.ralleratpower.de/f/Pologiesel.wmv)

:D good work

[sjampoo]

http://www.volksforum.com/albums/files/3/9/diesel_dyno_run.jpg


Mind you:

1) outside temperature
2) dieselpump not modified in any way
3) G-charger pully still stock, so on a diesel engine (lower max-revolutions) it's de-tuned compared to OEM petrol

4) I'm quite/very satisfied..

[Gallagher]

pump up the pressure now :)

[Kentuky]

Hello, I got a polo MK2 2f, 1.4Diesel and I have also a G-LADER, liked the project, I am thinking about doing the same, but liked a few more picts!
Thank you. Greetings from Portugal :)

[sjampoo]

Project 'closed' for now.

Will hopefully start and complete a stripdown, recolour, rebuild from 06-03-2009 to 06-03-2010...

[DÁ-BRT]

I saw that the project is on hold. But if you are stripping for rebuilding it I will offer you my support on upgrading the ve-pump. ;)

I like the project and the fact that you finished makes it even better!

[sjampoo]

Strip for FULL rebuild.

So, yes: If you would like to.. please, be my guest.. I'm still unsure about what and how to ' tune ' the engine, since I would like it to be on a dyno, but most companies don't bother with either Diesel or anything without a chip to be modded.. Some claim to be capable, but they are way to expensive..

I know you don't have a dyno, but you do have lost o experience.. If you dare to take the challenge, I will be grateful!! I hope there's some more horsies in there, but I would definitely like more torque!!

[sjampoo]

teaser

http://www.polo86c.nl/cpg/albums/userpics/normal_Leeg_20-04-09.JPG

More nudity in the (near?) future!

[Stijn]

Wow, that is a stripdown...you weren't kidding

[jellehier]

Cool, I see you're from Oosterbeek, That's the one near Arnhem right?

If that's true we are practicly neighbours, I'm from Schaarsbergen.

love the project of a diesel g-40

I want change mine to diesel too, but not a g-40, I wan't to fit a 1.2 litre tdi 3 cilinder.

[jellehier]

are there any updates here?

[Mark1]

Yeah, how about it Sjamp-meister ?
Show us some pics :D

[sjampoo]

I'm still alive, but the wife being pregnant and all, makes life change priorities :)

No, for real: Have been working on the car, but it's a shitty job cleaning things out.

http://www.steilheck.nl/cpg/albums/userpics/normal_bodem_na.jpg

Still need to get the rollcage sandblasted, but lack of transportation and vacation-closings is holding me back.

[sjampoo]

New colour: Pink!

[Oudelut]

:limey: :rock:

(Copycat! :D )

[Mark1]

New colour: Pink!

You're kidding, right ?

[Stijn]

You're kidding, right ?


From what I hear, it's his wife who will be kidding :D

[Mark1]

From what I hear, it's his wife who will be kidding :D

:D

Yeah...and no points for guessing why he's thinkin' of pink ( de colour that is :D ).

[Richard]

:D

Yeah...and no points for guessing why he's thinkin' of pink ( de colour that is :D ).
:D

[Polo1w]

I wonder, how's de giesel?
I know, it's bin a long, long time ago the giesel was operating, but i'm very curious if it is running again.
Greetings!