Stroker build

[rxl]

Wow.. I do love these kind of projects

[diesel des]

As I'm using 3b s2 oil and water pumps on a tall tdi block with AAN urs4 ancillaries some things were bound to interfere.

The water pump nose on its pulley is quite long and was interfering with the aan accessory belt Tensioner. So I cut off its nose, about 15mm, and tacked the pulley in 4 places to the shaft to ensure it won't move. All ground flat again.



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[diesel des]

The tdi block is taller and so I had to cut and set a piece of steel into the timing belt back plate. It's a 3b plate, and I am using a carbon 3b cover I got from aron on this site which is made to clear the Vernier cam pulley. Here is the backplate fitted and painted.





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[diesel des]

You will also notice in the above picture that I have modified the plastic deflector that sits on the cam to stop oil being flung out the oil cap if it's opened with the engine running. It's mounted on the other side now and it's purpose and position is to deflect the oil away from the drilled oil breather pipe in the cam cover.

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[diesel des]

So I had a sleeve made for the idler to increase its od to 81 mm. It was a tap on fit and I used bearing fit and a few tacks of weld to hold it.

This gave me a tight 151 tooth AAN belt with plenty of adjustment left.



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[diesel des]

Next up was the belt cover. I won't run an engine on the road with no cover as a single stone can kill a belt and reck a head or even complete engine.

I got a carbon cover off aron on this site and had to butcher it to make it fit the tall block. I had to extend it with fiberglass. Also this cover is the deep version to clear Vernier cam pulley.


My next issue was the accessory belt Tensioner hitting the bulge in the cover.



So I cut the bulge off!



And everything now fits. Here is a picture of the accessory belt on and clearing everything OK.



Next job is to fiberglass up the hole I have made. It just needs to be flat with no bulge to fit. Once that is done I will tidy up all the fiberglass and painted black to make it less obvious. Also were it's cut and modified is lower down and won't be seen easily when it's all in the car.

So tomorrow I will finish off that cover and hopefully a new crank bolt will be here so I can torque the poo out of it and that's the engine and box ready to go in....



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[diesel des]

Oh for completeness the accessory belt is 22mm longer than stock AAN to fit the tall block and spaces brackets.

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[caterpillar]

very nice sharing, theee small detalj... i DO like it....!!

[diesel des]

Cheers!

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[S2central.net]

Admiring your work Des and attention to details on the timing belt which brought me here from another thread.

[diesel des]

Thanks Paul. The engine is ready for dropping in but i have to change the boot on the steering rack first which is a complete operation. I'm working long hours and weekends at the minute so it's hard to get time and motivation. ..

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[S2central.net]

Tell me about - I am having a quiet week for the first time in like 6 months... but at least you are making progress !

[diesel des]

So an update. I managed to get the steering rack boot changed. It was a pain in the *** even with the engine out.

So today I dropped the engine and box into the car.

It has highlighted that my oil return on the turbo is a bit tight to the chassis leg so I will redo that.



Also as the block is about 16mm taller the inlet manifold touches the sound absorbing material under the bonnet. It still closes ok but but I will shim the engine down on its mounts about 10mm. There is about 20mm between the sump and subframe so there is space ok.

Next step is to make the new downpipe. There is plenty of room for the 3 inch setup.





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[newsh]

Good stuff, it's really coming together now

[diesel des]

I hope to have it making noise within a week. There I said it. It must happen now...

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