Tdi Replacement engine

**GyroLandy** · 21st June 2010, 12:53 PM

Ok, I've done some more research and this is what I came up with:

1. 2.5l to 2.8l Conversion kit including crank, piston, conrods, rings, head gasket etc. for $1,800 from M&D in the UK
2. Have the cylinders bored to fit the $2.8l as per specs from M&D - Does anyone know where I can have this done in Sydney? Presume this will be less than $1,000
3. M&D does a power conversion on teh head, turbo accentuator and fuel pump. According to them the upgrade accentuator provides more or less teh same as teh variable nozzle turbo found on the 2.8l TGV and fits a standard Tdi turbo. They charge a surchage but refund it once tehy receive the existing head - $1,200.
4. Have my exiting turbo redone - Does anyone know how much that will cost and who can do this? I thought thsi was in teh region of $1,000
5. Shipping cost to and from the UK - $500
6. Incidentals of $500
7. Are there any costs (excl. labor) which I have not factored in?

So the total is $6,000 excluding the labour cost which brings me back to the question... can I do this myself? I have re-done every suspension part of the vehicle and have rebuilt a motorcycle engine before so what are the odds of stuffing this up. Is there someone that can check it beofre I start it up to give me an opinion as to whether I have done something wrong.

So if I do it myself, I pay $6k for a 2.8l engine while retaining the original engine as a base and have a new turbo with higher capabilities and fuel pump.

There might still be new injectors required which can be done as and when funds are available.

Am I missing something here or is the above a good option that gets me the increased power?

**roverrescue** · 21st June 2010, 02:41 PM

Gyro,
I know the lines you are thinking along.
My situation is a little easier as it concerns a second block... ie I dont have off the road time constraints.

The 300 block I am doing up was dusted in its former life and all bores were shot.
I tossed up the 2.8 stroker kit but in consultation with a few people (Bush65 very helpful) decided that rather than minimal extra cubic capacity a VNT would give a more tractible engine. Cost wise not much in it, especially if you are thinking of spending money on the turbo.

I also had concerns with over boring the block 80 thou (specs for MD 2.8 kit) despite being told they have had no problems?

If I had needed to replace the crank I would have gone the MD stroker for sure...

Anyways, my engine work was done in Cairns, but I have had the block cleaned and match bored to a set of 40thou pistons. Crank ground to 20thou big ends, linished the mains (as a side note, on a poorly cared for dusted block the big ends were flogged but mains okay - this backs up what Rick130 has been saying for a whiles!) New camshaft bearings. All up got change from $600.

So now I wait till the AUD comes up against the pound and will then get in the allisport VNT kit, a new head plus plus plus. Then I change the radiator and fit a bigger IC...

Project end date who knows! But thats the plan.

S

**rick130** · 21st June 2010, 02:45 PM

Originally Posted by roverrescue

[snip]
I also had concerns with over boring the block 80 thou (specs for MD 2.8 kit) despite being told they have had no problems?

[snip]
S

You had the same concern as I did

http://www.aulro.com/afvb/technical-...ml#post1275252
Engine swap 300tdi to Isuzu 4bd1

**roverrescue** · 21st June 2010, 04:16 PM

yeah saw that thread... was going to reply that you can get 1.0mm (40thou) OS pistons for a 300tdi as the largest over bore. The 2.8 stroker requires you to double that out to 80thou!
Deep down I would like to put a rattly zoozoo in the 130 but I have a whole corner of the shed dedicated to 300tdi bits and feel I should use them up!

S

**uninformed** · 21st June 2010, 04:38 PM

spending $6k on something that has already failed once and are you adressing that problem.....along with the others that exsist in that engine/ vehicle???

dont forget to add to that list a new rad core and a new temp gauge, plus an egt gauge if you dont have one.

oh and if your going to spend that coin on the donk you may as well get it to breathe right and put a proper intercooler in + hoses

all these things MAY work out in colder climates, but In QLD and put it to work will only result in tears

**rick130** · 21st June 2010, 05:15 PM

Originally Posted by roverrescue

yeah saw that thread... was going to reply that you can get 1.0mm (40thou) OS pistons for a 300tdi as the largest over bore. The 2.8 stroker requires you to double that out to 80thou!
Deep down I would like to put a rattly zoozoo in the 130 but I have a whole corner of the shed dedicated to 300tdi bits and feel I should use them up!

S

Aftermarket pistons ?

RAVE only lists 10 thou and 20 thou as the only two OS sizes ?

Standard 90.395mm
First OS 90.649mm
Second OS 90.903mm

**roverrescue** · 21st June 2010, 05:24 PM

Yeah,
German made (cant remember brand name)
Engine builder who matches the pots to the pistons was very happy with tolerances.
He knew the brand and said they are the right stuff?

The reason we went 40 thou was number 3 and 4 pots were worn out past 20 and smooth as glass. Engine still ran okay, just used ole!

Can get brand / part number if needed.

S

**uninformed** · 21st June 2010, 06:52 PM

would it be MAHLE?

Serg

**slug_burner** · 21st June 2010, 07:20 PM

80 thou, approx 2mm, only 1mm off the cylinder wall. I'd like to think that there was more cylinder wall thickness than 2-4 mm. You would have to have a bad casting to be so unlucky.

Do 300 tdi's have liners? I guess not!

**roverrescue** · 21st June 2010, 07:48 PM

No liners in a 300 - cast block.

MD told me they have sold "lots" of 2.8 kits with no reported overbore faults.

Each to their own... With stock turbo / fueling will the extra stroke make an appreciable difference? I choose to spend $ on the induction side...
but, if the crank had been toast I would have gone for the 2.8 stroker?

S

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