iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

[iichel]

2.0 TDI CFHD particle filter 6R0254700RX
2.0 TDI CFHD front silencer 6R0253209B
55mm connecting sleeve 1K0253141M

The next step is to find a company to make a nice, custom, 1-pipe stainless steel end silencer.

[ciclo]

What adhesive paste have you used in the joints/connecting sleeve?

On the other hand, the ground protection fairings look great. The overall look looks very stylish.

[iichel]

[alexperkins]

Why is it all red

[iichel]

To annoy me...

I think it's some kind of anti-theft measure to stop people from tampering with it, upon installation or something. I don't know.
And the engine was bought in German, and having fun is forbidden in Germany. So if you want a nice and fun engine, it must be compensated by painting it pink.

[alexperkins]

How very strange. Does it come off easily?

[iichel]

Not really. It's spray paint and it goes everywhere.... and it's the proper sticky stuff, not the stuff that soaks off easily with white spirit.

[alexperkins]

Yuck! Thinners perhaps then but they can do major damage. Very strange to do that in the first place

[Lee_Liu_Te]

Good mod

[iichel]

Just some quick mathematics.

For a given engine, let's say the 2.0 TDI CFHD engine in my backyard
Stroke is 95,5mm
Bore is 81mm
Compression ratio = 18:1



Compression ratio = (swept volume + combustion chamber)/combustion chamber
Swept volume = pi * (bore/2)^2 * stroke = 492 cc
18 = (492+CC)/CC --> CC = 28.94cc



Head gasket comes in thickness 1,55mm, 1,63mm, 1,71mm (03L103383BM, 03L103383BN, 03L103383BP)
Volume of head gasket is [1,55 1,63 1,71] * pi * (bore/2)^2 = [7986mm3 8399mm3 8811 mm3]

With standard head gasket, combustion chamber = head gasket + residual volume
So residual volume = 28940mm3 - 7986mm3

Combustion chamber with 1.63mm = residual volume + 8399mm3
Doing some math, the compression ratio with 1.63mm
Compression ratio = (swept volume + combustion chamber)/combustion chamber
CR = (492cc + 28940mm3 - 7986mm3 + 8399mm3)/(28940mm3 - 7986mm3 + 8399mm3) = (492 cc + 29.36 cc) / 29.36 cc
CR = 1 : 17,75

Same trick with 1,71mm -->
CR = (492 cc + 29.77 cc) / 29.77cc
CR = 1 : 17,5

Lowering compression ratio can help an engine with severe boost levels.
Increasing compression ratio can help an engine with efficiency and horsepower

[iichel]

So, I had my exhaust replaced.

I already had the 2.0 TDI DPF and middle silencer.

Now I have a custom exhaust too, from stainless steel. Why? Well, I want to have the full exhaust in 55mm (2.0 TDI is 55mm, 1.6/1.2 TDI is 50mm).
The 55mm system is, in OEM, only available in a double tailpipe. I think one pipe suits my car better. And it's now stainless steel.









https://www.facebook.com/Celtemp/posts/4763171867035567

[ag69]

very nice!!!

[Lee_Liu_Te]

Good Job !!!
Before buying the Polo I decided to do a 2.0tdi swap, so I bought a cheap 1.2tdi. Time flies and other expenses appear all the time. Now I will be changing the entire suspension (90%), then the brakes (30%) and then Full Led (0%) . Lastly, I left myself a swap. Iichel I hope that if you do your own swap, you will let me use your experience, knowledge and lend me some help . I keep my fingers crossed for your project !!!

[ciclo]

very nice!!!

+1 ... a fine job!

O my god ... (nice)

[iichel]

Thanks guys. It's nice to see everything come together.

This morning, I delivered my car to the national motor department in Lelystad for it's official approval of the new engine.



They will test the handling, braking, power output and emissions of the car, and do a full technical inspection as well.

I'm hoping this will work out just fine. The car has always passed its regular inspections with flying colours.

Tomorrow hopefully the car will officially be a 1.6 TDI DSG

So far, just about everything else has been upgraded to accomodate a more powerful engine:
- Sports suspension
- WRC braking on all four corners
- Exhaust system
- Cooling package
- Intercooler
- Engine management
- ESP upgrade and coding
- Airbox + filter