MK6 Home made 2.2tdci, + various other mods!!!!

[winterheating]

ah no need now,
id put the 125ps transit into superchips and didnt come up with powergraph, so thought they didnt do them anymore
but they have them for 155ps,130ps mondy.

[winterheating]

i cant put the graphs direct on here or merge them together

http://www.superchips.co.uk/curves/mondeo22sttdci.pdf

http://www.superchips.co.uk/curves/mond ... 0bhp-d.pdf

[winterheating]

as i expected, to use the 2.4 head the 89,9 bore must be used for the valves to fit.

can anyone guess what it may run like with 86mm short stroke and the bigger bore
i'm guessing that torque and power will increase at higher revs , but doesnt mean i'll loose power and torque at low end than as it was

i'm going to have the engine just running the alt, to have a free running as possible engine.
and try and fit electric vac pump, pas pump, water pump, but fit some solar cells to the roof to try and take the load from alt.

[winterheating]

oh and has anyone got a mk6 2.4 135 tdci piston for sale, cos i think the tddis will be totally different like on the 2.0ones.

[Luke]

i'm going to have the engine just running the alt, to have a free running as possible engine.
and try and fit electric vac pump, pas pump, water pump, but fit some solar cells to the roof to try and take the load from alt.

you could fit a switch on the alt feed for the sprint runs when you bring it to ford fair and north weald next year

[winterheating]

i'm going to have the engine just running the alt, to have a free running as possible engine.
and try and fit electric vac pump, pas pump, water pump, but fit some solar cells to the roof to try and take the load from alt.

you could fit a switch on the alt feed for the sprint runs when you bring it to ford fair and north weald next year

yeah i'll do that aswell.
how long do i have till northweald

[Luke]

not sure on north weald need to get it sorted but it's usually around may time

[winterheating]

ah i plan in having it at least mobile again by then, may not be finished but mobile

[winterheating]

thought id put some pics up of my crew seats.


this is my poor van after taking all my racking out, its was spotless when i first got it, no rust or anything, i'd covered the floor with 3/4 ply, full wood bulkhead and, racking all round.
but it now needs re-newing and changing round to get it looking fresh again.[/i]









[i]made a moc bulkhead, and raised floor, and set 3 seats out to see what it would be like








frame for seats to fix to.




made a frame to extend front cab ceiling height, and fixed a new raised floor. Filled with space blanket were i could







filled the shelf above front cab with space blanket, and used a jack to hold down a full 3/4 ply top, so its nice and strong for anything i'll be storing up there.

[winterheating]

had some spare time today to try some con rods and pistons.

the 2.4 and 2.0 cranks are different as 2.0 has a 86mm stroke and 2.4 has a 94.6 mm stroke.

i need the 2.4 crank to use in a 2.0 block.

the 2.0 and 2.4 block heights are the same.

i took my old 2.0 75ps tddi pistons and put them into a 2.4 block, when at tdc the stuck out about 5mm

the gudgeon pin is different position on the tddi to a 2.0 tdci that i have

tddi 75ps has conrods with F lasered on

the 2.0tdci has L lasered onto conrods.

i connected the 2.0 tdci pistons onto the tddi conrods tried it in the 2.4 block and its perfect at tdc.

all i need to know now is the piston shape of the mondeo 2.2tdci to see what shape it is, so i know to use either mondeo 2.0 pistons or transit 2.0 tdci pistons.

i cant see ford making a unique piston for the 2.2tdci mondeo really though.

once ive found that out i can put it together.

[winterheating]

just to clear up the conrod lengths

on the 2.4 duratorque

The connecting rods are available in three different lengths. For identification, the large end and bearing cap are marked with the corresponding length code (H to J):

l H = 149.74 mm

l I = 149.80 mm

l J = 149.86 mm

Only connecting rods of the same length must be installed.

this matches with the 3 different thickness head gaskets.

and on the 2.0 duratorques

The connecting rods of the 2.0L engine are divided into the following length categories:

l E = 154.94 mm

l F = 155.00 mm

l G = 155.06 mm

The piston pin is 71 mm long in all variants.



ive also just found this in the 2.0 transit duratorque section thats quite confusing
seems.


Cylinder Head Dimensions - 75/85 and 100 PS engine
³ Description ³ mm ³
³ Maximum distortion Ä measured longitudinally and diagonally ³ 0.10 ³
³ Peak to valley height of mating surface ³ 0.02 ³
³ Thickness of cylinder head gasket with piston protrusion of 0.300 - ³ 1.1 (one hole/tooth) ³
³ 0.400 mm ³ ³
³ Thickness of cylinder head gasket with piston protrusion of 0.401 - ³ 1.15 (two hole/teeth) ³
³ 0.450 mm ³ ³
³ Thickness of cylinder head gasket with piston protrusion of 0.451 - ³ 1.2 (three holes/teeth) ³
³ 0.500 mm ³ ³


Cylinder Head Dimensions - 115 PS engine
³ Description ³ mm ³
³ Maximum distortion Ä measured longitudinally and diagonally ³ 0.10 ³
³ Peak to valley height of mating surface ³ 0.02 ³
³ Thickness of cylinder head gasket with piston protrusion of 0.430 - ³ 1.1 (one hole/tooth) ³
³ 0.520 mm ³ ³
³ Thickness of cylinder head gasket with piston protrusion of 0.521 - ³ 1.15 (two hole/teeth) ³
³ 0.570 mm ³ ³
³ Thickness of cylinder head gasket with piston protrusion of 0.571 - ³ 1.2 (three holes/teeth) ³
³ 0.620 mm ³ ³

[bigjohnthomas]

the inside of your van looks worse than mine dose after being constantly wet for 5 years washing dogs bums wtf have you been doing in there?
interesting to see what a longer throw crank will be like in a 2.0 as long as your pistons dont rattle to bits 8.4 mm x3000rpm x4 is a lot of compression

[winterheating]

when i got the van about 6 years ago now it was spotless, then i ply'd it all out, had racking at side door only and some more racking straight up to bulk head, id just ripped it all out then, god knows why it had got so mucky, i thought it would be spotless still

well with compression, i need to get it down a bit, the correct 2.2 tdci is only

Powertrain
Type of engine In-line
Cylinders 4
Engine installation Front mounted engine, transversee
Cubic capacity 2198 cm³
134 cu.in.
Max. power output 114 kW
155 PS
~ 152 hp
@ 3500 rpm
Bore x Stroke 86.0 x 94.6 mm
Compression ratio 17.5:1
Valves per cylinder 4
Valvetrain Dual Over-Head Cam (DOHC)
Fuel injection Diesel direct injection
Charger Turbocharger
Max. Torque 360 Nm
266 lbs ft
@ 1800 rpm
Drivetrain serial Front wheel drive
Manual gearbox 6
Automatic transmission None
Displacement-to-power
ratio 51.8 kW/l
70.5 PS/l
~ 69.1 hp/l



Performance
0 to 100 km/h
(~ 0 to 62 mph) 8.7 sec.
Top speed 223 km/h
~ 138 mph
Weight-to-power ratio 12.9 kg/kW
9.5 kg/PS
~ 9.7 kg/hp


i could do with a compression calculator, to see what using the 3 notch gasket and the shortest conrod would do
or even what just using the conrod i have 155mm with the thickest 3 notch gasket.

[winterheating]

the inside of your van looks worse than mine dose after being constantly wet for 5 years washing dogs bums wtf have you been doing in there?
interesting to see what a longer throw crank will be like in a 2.0 as long as your pistons dont rattle to bits 8.4 mm x3000rpm x4 is a lot of compression

so basically if its got a longer stroke it will be pulling in a lot more air
so really the correct 2.2 pistons will have different cc pistons to overcome this
or will the thicker HG be enough

[winterheating]

using this calculator
http://www.vwspeedshop.com/Engine%20Calculator.htm

to get the correct compression ratio for the 2.0 86x86mm of 19:1 the combustion chamber cc needs to be 28

to get the correct compression ratio for the 2.2 86x94.6mm of 17.5:1 the combustion chamber cc needs to be 33

think i'll need to get the actuall 2.2 pistons now