Jump to content

Engine rebuild

printedflunky
 Share Followers 0

Recommended Posts

printedflunky

printedflunky 9

Posted
Posted (edited)

My VR started running like an angry badger last week so I took it to a VW specialist and they called me a few hours later telling me that it was either a burnt valve or a piston ring had shat itself either way I was looking at having to shell out a lot of cash to repair a 182000mile vehicle, so I did wht any sane person would do;

I ordered:

a new block

6 new standard pistons

a set of genuine piston rings

a set of genuine gudgeons

a genuine set of wrist pins

an R32 crank

and a set of custom made conrods (5.8mm shorter than standard)

also sent a spare head I had lying around to a cylinder head tuner in Hastings for:

porting and polishing

5 angle valve seats

larger diameter vales (inlet and exhaust up by 2mm and 1.6mm).

Then obviously a complete gasket set, chains and tensioners set, head bolts and other shiny bits from techtonics tuning in the states.

 

Totally sane and rational actions from a totally normal VR owner :)

Edited by printedflunky
Link to post
Share on other sites
printedflunky

printedflunky 9

Posted
  • Author
Posted

Dare I ask how much that little lot set you back?!

It's not as much as you might think to be honest, as I said in this^^^^^^^^ post I got the block, pistons, piston rings, gudgeons and wrist pins for the princely sum of £465

the R32 crank was £150 from a local scrappy

the custom rods are £140 each

the TT bits were $685 roughly £425

supatech valves were £150

the head work is yet to be completed but he quoted me £15 per port (x12=£180) £12 per valve to enlarge to bigger diameter plus another £8 per valve for the 5 angle seats.

total spent and commit to spend is somewhere close to £2500

Link to post
Share on other sites
printedflunky

printedflunky 9

Posted
  • Author
Posted

Interesting, What extra displacement does the R32 crank give?  Im assuming its longer stroke than standard.   

The crank has a stroke that is 5.8mm longer than the 12v vr6 which is 95.9mm

so it will give :

pi(40.5mm^2) x 95.9mm= 494157.8714625mm^3 per cylinder

x6= 2964.947228775cc

so in general terms it'll make it a 'real' 3lt vr6

Link to post
Share on other sites
printedflunky

printedflunky 9

Posted
  • Author
Posted

I'm hoping for a stable 200 ponies without changing the camshafts and exhaust. Once the engine has bedded in and covered a couple of thousand miles I'll replace the cams and exhaust, get it put on a rolling road and get it live mapped. I would hope for 220hp without over stressing the engine. The whole idea behind not boring out and putting oversized pistons in was partly down to cost but mostly down to the fact that I don't want to drop reliability or thrash-ability (not sure that's a real word).

The cylinder head shop.com thinks he'll be able to increase the flow rates by 30% but I don't know how that will transfer to power increase.

Link to post
Share on other sites
  • 3 weeks later...
printedflunky

printedflunky 9

Posted
  • Author
Posted

Arrrghhhhh! Need assistance, just spoke to the engineering firm and during conversationhe asked what I was using the new 'rods for so I told him what the plan is, he instantly replied with a question that I know I should have asked myself when I started all this:

"have you taken into account for the increased volume there will be an increase in compression ratio?"

 "shite" was my rather eloquent reply.

Subsequently I've been trying to work out how high the compression ratio will be if I leave the order on the 'rods as is.

If anyone here could assist with the piston to deck figures, dish volume of the stock pistons and the compression height I would be very grateful so I can adjust the order and start the build proper.

Link to post
Share on other sites
ssaunders

ssaunders 199

Posted
Posted

Hi, How about this deal from ebay.de

http://www.ebay.de/itm/VR6-Turbo-Motor-KOMPLETT-EINBAUFERTIG-GT30-HF-Golf-1-2-3-Corrado-Passat-Jetta-/181209939158?pt=DE_Autoteile&hash=item2a30f43cd6

 

here is a rough translation, all for about £3300

The basis is a good used VR6 engine on which the following
Were installed or replaced parts :
RF GT30 turbocharger 0.82AR (replica in TOP Quality)
Turbo exhaust manifold
DIY RS2 wastegate
76mm downpipe wrapped with heat protection
470ccm injectors
Software tuning " Turbodödel " to 1.8 bar
Short intake manifold with side exit
New thermostat housing with a pipe
Oil supply and oil return lines
Water supply turbocharger
Timing Chain Kit ( original VW)
R36 big end bearings with new bolts
Exhaust manifold NEW
Ansaugbrückendichtung NEW
Cylinder head bolts NEW
Oil pan gasket NEW
Compaction reduction by 2 x metal head gasket + plate
New oil filter and new water / heat exchanger
6 new spark plugs RS4
The motor is according to customer
either ausgetattet with distributors or static ignition !
The engine is supplied without a plug wire !
 
Performance expectations :
 
About 450 hp at 1.8 bar boost pressure.
 
This performance is easily navigable for the motor with stock pistons and connecting rods .
From about 500HP then H -Shaft connecting rods as well as modified stock pistons should be installed.
From about 700hp then forged pistons are needed.
 
Optional changes:
 
There are generally all turbocharger possible such as: Garrett GT3076R , GT3582R , etc. ..
and T3/T4 or Precision turbocharger , prices on request.
Other connecting rods, pistons and all special requests are also feasible and available on request.
Of course, installation is also possible - price on request .
Delivery time is approximately 1 week.
Link to post
Share on other sites
 Share
Followers 0
Go to topic listing
×
×
  • Create New...