.

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

Teaser:





Notice anything new?

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!










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




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..




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 :)




Anyway: back on project:

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




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:




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).




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...

it looks good buddy, i was really impressed!

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..

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!

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 :)

This one Gallagher?




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 :)

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..

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 ?

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.




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'



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.

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 :)

:screwy: green paint :screwy:

the rest :thumbup:

Race you to the altar! :)

LOL, you got me beat already

did winn 9-9-99

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

* finally the 1.3 diesel died on me on *



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..




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?


But only just;


(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:



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.

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

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.

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!

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.

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

Cool! Very cool!

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.

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

COOL!!!!

I need to start building a G60D now :)

Did I say I was a Pic-Whore allready?

I didn't?

Must have said so before....

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.

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

Looks hot!

very impressed Sjampoo.. very impressed

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! ;)?

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

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

I love it!

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

wheels spinning in a diesel polo..:D