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 Post subject: Re: 5-Cylinder turbo golf
PostPosted: Tue Apr 25, 2017 9:37 am 
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Joined: Tue Dec 15, 2015 2:54 am
Posts: 33
Location: London, UK
ECU Model: S100 Pro
Distributor: Direct
Firmware Version: 73.01
They are ten-a-penny in the USA, so cheap to buy on eBay.
Shipping it here was a bit of a nightmare though.
I see TT-RS engines for sale on German eBay for 10,000 Euros...... :o

More updates coming soon. Bottom end is still getting machined.

The spare head I bought arrived. Stripped it down. I will probably use that one as the cam journals look a bit worn on the head that came with my engine. Something went wrong with that one to cause the cam lobes and rockers to get so pitted.

The head design is a work of art. The walls of the exhaust ports are relatively thin and bathed in oil to help cool them down. Its such an intricate casting. Will post some photos.

I still cant get my head around the rocker arrangement in these engines. I'm familiar with old V8 pushrod/rocker where they are all slotted on a central shaft which forms a pivot point. Pushrod moves one side of the rocker up and the other side presses down on the valve.
On the VW engine however the rocker is completely floating - one end clips to the tappet (which moves), the other end sits on the end of the valve (which moves) and the cam lobe (which also moves) contacts the middle of the tappet.

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 Post subject: Re: 5-Cylinder turbo golf
PostPosted: Sat May 06, 2017 3:06 pm 
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Joined: Tue Dec 15, 2015 2:54 am
Posts: 33
Location: London, UK
ECU Model: S100 Pro
Distributor: Direct
Firmware Version: 73.01
So, I bought a spare head from the USA and when it turned up it was in better condition than the one I already had. So I'm going to use that one instead.

Stripped it down completely. The seller had cleaned the head in a parts washer which makes it so nice to work with - no oil or grease.

I had read on a couple of forums that the cylinder heads for these engines flowed extremely well in standard form and having examined for myself I can see why. The throats are matched very well to the seats. There is no casting flash or other protrusions. However...

A lot of these heads incorporate EGR for emissions reduction. Both of the heads I have feature this.
On close inspection there are a pair of holes next to each exhaust port.
Image

Each hole is drilled right through to the throat of each exhaust valve. This means that there is a gaping 7mm hole right on the radius behind the exhaust valve. A hole is then drilled crossways through the head which joins all of the smaller holes together, the EGR valve connects to this. I wasn't happy with this arrangement, cant be good for gas flow. So I drilled and tapped them through.
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I made some studs from aluminium threaded rod.
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Installed with high temperature thread locking fluid.
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The ends are just proud so I can gring them down when porting and polishing.
Here you can just about see the other hole in the adjacent valve throat.
Image

Bit of a boring update, I know. I'll be starting on the porting job next week hopefully so will post up some pics of progress. Not much to do really, just smooth the walls and match the inlets to the manifold.

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 Post subject: Re: 5-Cylinder turbo golf
PostPosted: Tue Jun 06, 2017 8:37 am 
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Joined: Tue Dec 15, 2015 2:54 am
Posts: 33
Location: London, UK
ECU Model: S100 Pro
Distributor: Direct
Firmware Version: 73.01
Woo!

The block is finally ready to collect from the engineer. It's been there for 8 weeks, hence not many updates. There wasn't that much to do on it (overbore, line hone, reface), I think they were just a little bit slow.

In the mean time I have been getting on with the porting and polishing of the head and matching it to the inlet manifold. Will post some pics soon.

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 Post subject: Re: 5-Cylinder turbo golf
PostPosted: Thu Jul 06, 2017 4:48 pm 
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Joined: Tue Dec 15, 2015 2:54 am
Posts: 33
Location: London, UK
ECU Model: S100 Pro
Distributor: Direct
Firmware Version: 73.01
Update on the head work. The studs to block the EGR channels were ground down;
Image

Then blended the valve guides into the ports.
Image
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The Audi TT-RS inlet manifold splits into two sections; the plenum and the runners. Because that engine has FSI the runners have 'tumble' flaps which suits that style of injection. I wont be needing any of that so I removed the flaps. I will be welding injector bosses into each runner so the flaps would have gotten in the way.

One of the benefits of the manifold splitting in half is that I can polish the inside of the runners and blend them to the ports on the head.

Before;
Image

Port matching done, still need to polish the inside though;
Image

Polishing the chambers now;
Image
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Ports more or less finished now too;
Image

Now some bling. My local engineer has a guy that does vapour blasting which is great for deep cleaning metal parts. I had all of the larger alloy bits done such as the alternator bracket, timing chain cover etc. The pic below is of the upper sump pan. It looks better than new;
Image

The Audi engine has a nice red valve cover but the VW engine only had a plain black one as it had another cover over the top. I couldn't resist getting my one painted red. The guy at my local finishers did such an awesome job. They used a high temp matt paint.
Image

I stripped down the propshaft and had the sections powdercoated matt black;
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Next up, HT black paint on the block;
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At the back of the block was a boss. On the Audi engine the boss is tapped for a coolant feed for the turbo. I asked the engineer to drill and spot face the boss on my block so that I have the option to do the same. It makes the coolant pipework much tidier.
Image

Mains studs and new bearings in;
Image

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 Post subject: Re: 5-Cylinder turbo golf
PostPosted: Sat Jul 08, 2017 2:45 pm 
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Joined: Tue Dec 15, 2015 2:54 am
Posts: 33
Location: London, UK
ECU Model: S100 Pro
Distributor: Direct
Firmware Version: 73.01
JE oversize pistons, forged rods and ARP AGE625+ hardware;
Image

All bolted in, with calico coated bearings. You see see where material was removed from the counterweights during the balancing.
Image

The sump is made up of two sections; a steel lower pan and an aluminium upper section which acts as a sort of windage tray and baffle.
Image

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 Post subject: Re: 5-Cylinder turbo golf
PostPosted: Sat Jul 08, 2017 3:30 pm 
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Joined: Tue Dec 15, 2015 2:54 am
Posts: 33
Location: London, UK
ECU Model: S100 Pro
Distributor: Direct
Firmware Version: 73.01
I bought an accurate set of scales. One of the pistons required a bit of filing but the rest were very close. I was able to get the pistons, pins, rings and locking pins into matching sets to within 0.1 grammes.

The balancing work was done by Swaymar Marine. The guy down there, Dave, clearly didn't like working on 5-cylinder engines, he wouldn't stop bitching about it. He had to fabricate a mandrel to hold the crank on the balancing machine so they are able to do these now. The TT-RS crank would fit on it too.

I provided the weights for the statically balanced parts to Dave. He weighed and balanced the rods. The photo below shows the bob weights that have to be added to the 5-cylinder crank. I think he did a great job in the end.
Image

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