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IHI VF34 Conversion Pics

Discussion in 'A3/S3 Forum (8L Chassis)' started by HTC, Dec 19, 2007.

  1. simch
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    simch Active Member

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    They are a pain to strip out!!

    Send it over to Dave Grissel and haev it ported and rebuilt by him!! Far easier and will flow nicer too!
  2. HTC
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    HTC Active Member

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    Who is Dave Grissel? Contact details?
  3. h100vw
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    h100vw Member

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    Will do that in a short while Kev

    Kev, I make the big end od as 30mm, id is 21mm and the small end od as 25 mm, id 18mm. It wouldn't take much to have the small end machined down a bit. I would do it with my angle grinder if I had to.

    Failing that, a man with your talents wouldn't spend too long working out a way to do it on the bench.

    The tool has a reach of 6 inches.

    HTH

    Gavin
  4. HTC
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    HTC Active Member

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    Cheers Gav. Grinding that down wouldn't be an issue. I've seen another option where a guy has use a large G clamp with a modified socket. See below:

    [​IMG]
    [​IMG]

    Would probably be a little slower. I'll see how much these G clamps are, but I'll probably end up getting the proper tool knowing me.
    Will be purchasing a bolt stretch gauge as well for the rod bolts. I prefer this method over a torque wrench.

    I don't suppose you know if the OEM rings require gapping do you?
  5. h100vw
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    h100vw Member

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    I don't know for sure but I don't see it likely TBH.

    Are you just going to bust the glaze and chuck in the new rings?
  6. HTC
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    HTC Active Member

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    Yep, thats about the size of it. I have a flex-hone............wish me luck!
  7. jim s3
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    jim s3 Member

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    i was doing that 2 weeks ago lol
  8. RichA3Turbo
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    RichA3Turbo ...Watching you! Staff Member Moderator

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    I think i was unclear. Head is most definitely coming off. Got all my parts, starting tuesday:)
  9. s3_kev
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    s3_kev Stage2'd!!!!!!

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    where did you get the engine mounts from im interested in some, thanks
  10. HTC
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    HTC Active Member

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    Okay Rich, thought that might be the case. Will you be using a stretch gauge for the rod bolts. Got myself one of these the other day. Supposed to be best way to tighten the big ends.

    Got them from these guys --> http://seatcupra.net/forums/showthread.php?t=178365
  11. s3_kev
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    s3_kev Stage2'd!!!!!!

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    nice one cheers for that there quite cheap to, i will have to get me some of them
  12. RichA3Turbo
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    RichA3Turbo ...Watching you! Staff Member Moderator

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    Nope...just good old torque wrench. They are ARP studs, so not stretch bolts.

    Took the head off today. What a b*stard of a job! Its a really easy job, that would have taken me an hour, tops, if it hadnt been for the manifold bolts / turbo bolts .etc. Wasted my day, and a fair bit of blood loss on that. :banghead:

    Pistons and rods come out tomorrow and new ones go in. Hope to have the majority of it all reassembled tomorrow

    Rich
  13. recomdos
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    recomdos Member

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    was that in the rain too Rich? I'm sure that makes everything twice as difficult! ;)
  14. RichA3Turbo
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    RichA3Turbo ...Watching you! Staff Member Moderator

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    Thunderstorm actually!:keule:
  15. HTC
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    HTC Active Member

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    Rich, did you received ARP 2000 bolts with your rods? If so, these ARE stretch bolts and needed to be tightened to .006" of stretch. If you can't get to a stretch gauge then you need to torque 3 times using the thread lube (tighten, untighten etc). But it will be a bit of a guess.

    Bolts on mine are a little easier than on the jabba mani...still going to be a few swear words I'm sure. Going to make a bent spanner this time round I think.
  16. RichA3Turbo
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    RichA3Turbo ...Watching you! Staff Member Moderator

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    Kev,

    thanks for the info. Hadn't even got around to checking out the torque figures yet. I'll see if i can get hold of one, but failing that what torque should they be tightened too?

    Pistons are out and cleaned and ready for re-assembly.

    Rich
  17. HTC
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    HTC Active Member

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    Torque spec for those bolts is 50 ft/lbs. If they are nice and clean and lubed up, you should be okay. Don't go over. If you stretch the bolt by as little as .001" you'll ruin it with regards to correct clamping and strength.
  18. RichA3Turbo
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    RichA3Turbo ...Watching you! Staff Member Moderator

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    Cool. ok.

    btw - the sump is a b*stard to get off too. The 2 bolts nearest the gearbox require a universal joint on a thin socket extension to get the out. The bores are looking in surprising good shape considering. Will be interesting to see what yours look like. When are you starting?
  19. HTC
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    HTC Active Member

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    I'm waiting on a few things. Possible headwork, researching the new turbo choice and some tools.

    Will make a start when it's all finalised. Probably going with a different tuner for software too.

    Cheers for the heads-up on the sump bolts.
  20. A3_Turbo
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    A3_Turbo Swaying towards IHI....

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    Saw you last nite at No-rice.

    Jeez could have at least cleaned her :yes:

    Jason
  21. HTC
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    HTC Active Member

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    Should have come and said hello. One of these days I'll dig out the sponge :)
  22. Mikey
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    Mikey Member

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    superb thread. good skills.
  23. RichA3Turbo
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    RichA3Turbo ...Watching you! Staff Member Moderator

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    I see from your pic ;) That would most like be my choice too should i come to change. Pistons are back in, big ends torqued up. Head going back on after lunch and then the rest of the re-assembly...the easy stuff! I used a sealey ring compressor to pop the pistons back in...biggest pile of sh1te... The ratchet kept undoing so had to hold it tight with one hand and tap the piston in with the other being careful not to damage the rings. All good now though.

    Will post up some pics later.
  24. HTC
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    HTC Active Member

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    Nice work. I've heard the tapered compressors are a bit easier, just a little expensive. I look forward to the pics.
  25. RichA3Turbo
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    RichA3Turbo ...Watching you! Staff Member Moderator

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    Not the greatest or most useful pics, but was hard to take pics with filthy hands and arms when there was anything insteresting.

    Anyway, pic of installed pistons and rods from top and underside.

    [​IMG]
    [​IMG]

    You can just about see the big ends in the second one. Everything was in surprisingly good condition considering.

    Head is back on and most other bits and piece too. All that is left to do is timing belt, aux drive belt and intercooler pipework to go back.

    Rich
  26. RichA3Turbo
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    RichA3Turbo ...Watching you! Staff Member Moderator

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    All done. Compression is even at ~170psi on all 4 cylinder and started first time OK. Job done.

    Im aching a little mind!
  27. HTC
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    HTC Active Member

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    Nice work there. Glad everything is in order. Time to rag it around in confidence........or buy a bigger turbo :)
  28. RichA3Turbo
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    RichA3Turbo ...Watching you! Staff Member Moderator

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    Or both :) Need to replace the clutch next. Was going to do that this week too but ran out of time. Will give it an easy 300 miles or so to run it in and then open it up properly.
  29. HTC
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    HTC Active Member

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    If you used the existing piston rings then you probably don't need to worry about a run in period.
  30. RichA3Turbo
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    RichA3Turbo ...Watching you! Staff Member Moderator

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    nah i changed the rings. Thought i may aswell while it was in pieces.
  31. HTC
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    HTC Active Member

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    Little update. I've now added a Walbro fuel pump. Mounted it under the car rather than in the engine bay like some. I'm still trying to keep the bay as OEM as possible.

    Also decided to buy a new turbo. My car still isn't boosting right. Most of the time it will be okay, but the odd time it will overboost as before. I've been though everything and the people I've spoken to all suggest boost creep or a cracked turbine housing. Whatever is up, its whistling above 22psi and I need to keep watching the boost gauge. Can't reliably boot it.

    So in the search for a better unit I grabbed a TD05H-18G hybrid. It's a Blouch item sourced through Scooby Clinic. Has the stronger 14psi (1bar) actuator and a ported turbine housing to hopefully eliminate all boost creep.

    It's a bolt on replacement for the subaru engine so the compressor and turbine housing are oriented differently to how I need them. So I decided to rotate the housings to suit the 1.8T (some people call it "clocking").

    As it came:
    [​IMG]
    [​IMG]
    [​IMG]

    18G vs K03
    [​IMG]

    Oil and water fitting removed.
    [​IMG]

    After removing a large circlip for the compressor housing, the clamp ring for the turbine housing and the actuator it was possible to slide off the housings and remove the CHRA.
    No balancing is required if the CHRA is left untouched as I have done.

    Turbo disassembled:
    [​IMG]

    Subaru turbos have a pin inserted into the turbine housing that locates with a hole in the CHRA for correct orientation. Obviously I needed to remove this to re-orient for the 1.8T. Five minutes with the dremel was required to grind it flat.

    [​IMG]

    View of the ported tubine inlet:
    [​IMG]

    Then all that was required was to re-assemble.

    Back together with housings pointing in the correct directions:
    [​IMG]

    The turbo is now pretty much ready to go on but due to the modification I'll need to weld on a couple of bosses to bolt the actuator to (area circled in pic). Shouldn't be too difficult. Bought some aluminium offcuts off ebay for the job.
    [​IMG]

    Not sure when I'll get stuck in fitting it. Going to do the engine work at the same time. I'm waiting on some machine shops to get back with prices on some head work. Mainly fitting the new valve guides. If anyone knows of a good place in the south, then let me know.
  32. h100vw
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    h100vw Member

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    Nice, are you going to run it with the same software for a while after the new build?

    Gavin
  33. HTC
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    HTC Active Member

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    It will need new software as it pumps a fair bit more air than the VF34. I will run it around on the old map for a while as I'll be bedding in the new piston rings so not to heavy on the pedal.
  34. s3_kev
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    s3_kev Stage2'd!!!!!!

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    your cars mental mate you spend a fortune on it, what hp you aiming for now then??
  35. HTC
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    HTC Active Member

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    Can't be sure what the power will be at the moment. I know of a golf with the same turbo running about 360bhp. I'd like to see torques into 300s also.
  36. abdus
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    abdus Top Gear

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    lol, should be fun driving this with 360bhp.
  37. jimbobery
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    jimbobery S3

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    Any update HTC?
  38. HTC
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    HTC Active Member

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    Won't be much to update on for the moment. I'm off to Saudi and Egypt for work for a short while. Also waiting for simch to get back to me about head work.

    I did buy one of these boost controllers yesterday just in case I need it. If not, I'll sell it on.

    [​IMG]
  39. simch
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    simch Active Member

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    My guy can do whatever you need with your head, but he agreed it would be best for him to see it assembled and together as it would need a check at those sort of miles befroe too much is disturbed.

    Is it nitrided inlets and inconel exhausts you have?
  40. S3KO4
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    S3KO4 Member

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    what happend? did you fit the turbo? or did I miss something. I searched it through google.

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