so it starts: PPT 3071 "build"

[jstnGTI]

so, after a long awaited big turbo dream of mine, I finally got started.
did MAD research, got a little bit of money, and called Arnold at Pag Parts. very good decision.

the wait from order to delivery turned out to a couple weeks, which worked out well because it gave me time to gather my parts.
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somebody asked me for a list of things I need for this build. This might help others:

I can try, haha. had to buy a lot of things along the way.

ppt v banded 3071 kit:
Gt3071r turbo
38mm tial mvs w/ open dump
ppt exhaust manifold
ppt custom intercooler w/ garret 550 hp core
tial Q bov
3" downpipe
Seimens 630cc injectors
Walbro 255 inline fuel pump
AEM dry flow filter
ppt 3" turbo inlet pipe
Audi tt intake manifold
Ic Piping by Arnold at pagparts
2.5" 42dd cat back

IE rods: rifle drilled, arp rod bolts
oem main bearings
oem piston rings
oem head bolts
timing belt/tensioner
water pump w metal impeller
new head gasket, valve cover gasket, intake/exhaust manifold gasket

Sachs vr6 clutch kit w/single mass g60 flywheel
Maestro 7 tuning suite

fluids, tools, clamps, hoses, etc. etc.
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and so I started shopping:
ariving first was gasket set ( head, valve cover, intake, coil pack), piston rings, and head bolts.


next up was timing kit, water pump w/ metal impeller and some g12.


then came IE rods w/ rifle drilling and oem bearings.


My collection started building and my turbo kit was a week out from shipping, so yesterday I started work:



with the core support removed, I started unplugging/labeling the harness, and disconnecting anything holding the motor into the frame.


downpipe was a bitch to unbolt, haha


gettin ready to come out.


"SHE'S AIRBORNE!"




some love for the 1.8t. first motor I've pulled, so I was pretty excited.


then, I started stripping/prepping it for things to come





Motor has not even 74k on it. Valve cover off, cams look great, timing chain looks great:


currently sourcing a poly drive head bolt tool, so progress has come to a halt. problem should be solved in the next couple days.
Clutch comes today, And fingers crossed my kit ships today, if not, it definitely will tomorrow.

Edit:
thank you, brush research:


thanks for viewing! comments welcome.

[jstnGTI]

So, i made a shi-ton of phone calls, finally got pointed in the right direction to a little place called "tool town," that had my polydrive tool. FOR $12! i felt like i stole something because i saw it going for $35 around the internet.


with this awesome find, i was able to press on and remove all ten head bolts in the proper sequence.
TDC:

head removed:

lots of carbon buildup. not sure what to attribute that to, but i'm not going to worry too much about it, clean it up, and press on.


flipped the motor over, and began removing all four pistons.


pistons out: gotta clean up all the oil from the cylinder walls, of course.



crank is in great shape, and oil pan was spotless.





when i get a second wind, i'll start separating oem rods from pistons, attach the IE ones, clean up carbon buildup from on top and between piston rings and install the new ones to spec.

btw, clutch kit came in yesterday:

-SACHS VR6 Clutch Disc
-SACHS VR6 Pressure Plate
-SACHS OEM Throw-Out Bearing
-SACHS Single-Mass 14 pound "G60" Flywheel

that's all for now, still waiting to hear from arnold about my kit shipping! ICAN'TWAIT!

[jstnGTI]

happy belated 4th everyone. I want to thank all my fellow military members for serving, and all the vets for giving their lives, sacrifices, and service for our freedom.

As a small update, I've cleaned up the ins-and-outs of my pistons, assembled the rods, and cleaned up the deck of my block.

I chose not to use that 3m pad, as it was too abrasive. Ended up using a really fine 3m pad that is used for smoothing surfaces between coats of paint. something similar to the surface of a sponge.

all cleaned up and assembled.

block looks good, still need to show my head and valves some love.


next up is deglazing the cylinder walls, piston ring gapping/install, and installing the pistons and bearings back into the motor. hopefully I'll have this accomplished in the next couple days.

Edit:
just finished (1&2)

(3&4


surprising myself every day at how fast I'm learning and how fast progress is being made. still trying to make sure I hit every mark and don't miss a step! BT is becoming a reality, hahaha.

yesterday got all my piston rings gapped, clocked, and installed. rods/bearing went in smoothly, just need to torque things down to spec, and I can start buttoning things up. oil pan, head gasket/head goes on next.


thanks for watching!

[jstnGTI]

IT'S HEEEEEEEREEEEE!

Christmas on my doorstep.
always a good sign:

I was too excited to take pictures so this is the aftermath, haha


tial q bov

external wastegate, also by tial

PPT exhaust manifold, welds look awesome


TIP, open dump from wastegate, table salt, everything v-banded

walbro inline fuel pump, siemens 630cc injectors

and finally! gt3071r


can't wait to get all these goodies in.

still waiting on maestro, and audi tt manifold. Maestro shipped separately from eurodyne, so that should be here this week. I'm going to expedite the shipping on my manifold so I can get this bad boy buttoned up and ready to boost!

[T-Boy]

Cool build...good choice of company and hardware! You'll like the 3017r

[jstnGTI]

I cannot wait! tryin' to do it right the first time, learned a lot from other builds.

[mylesp]

Awesome ! Will be watching

[Big_Tom]

[Rod Ratio]

Subscribed

[weenerdog3443]

nice build you got going.. good luck with it

[Three3Se7en]

Your shirt looks pretty clean.

[jstnGTI]

Your shirt looks pretty clean.

i can't count how many white v-necks i've trashed working on the car. luckily they come in 5 packs! hahaha

[Big_Tom]

Your shirt looks pretty clean.

[jstnGTI]

bump for small update.

sn: my left thumb hurts from putting those cir-clips back into the pistons. barely got the fourth one in, haha.

[sledge0001]

Nice!!!!

[gdoggmoney]

That is normal carbon buildup for a VW. The PCV systems are super dirty. That leads to coke on the piston crowns valves and etc.


Looking good!

[Glasser]

Good work man! Especially for your first time, I've pulled motors but never broke one down to the internals but it looks like fun

[adgoff21]

Sent from my DROID2

[jstnGTI]

bump, significant update.

[formerly silveratljetta]

dream build

[Big_Tom]

IT'S HEEEEEEEREEEEE!

[Three3Se7en]

I love the Tial Q BOV. No fluttering there. Nice parts too. VBand everything.

[87vr6]

Sweet man, for the record, you can use a 8mm (i believe) allen key to REMOVE the poly drive bolts, but not reinstall them. For future reference for other people really, seeing as you have the tool now

[jstnGTI]

ran outta reserve pages. thanks everyone for the positive feedback!

so today, i did MAD work. I did all I could before the excitement made me tired enough to stop.
was working really hard, so less pictures were taken.
I put the arp rod cap bolts through two torque cycles before their final resting position. checked the sides with my feeler gauges for clearance and all went well.

so I started buttoning things up.

oil pump, baffle, and oil pan back on, fresh head gasket:

got the water pump on, timing belt tensioner, and timing belt. this part was kind of stressful for me because sh!t kept moving when I tried to put the belt on the tensioner. luckily i got it first try and everything was at TDC, so I was able to press on.


then I started to have fun

v-bands made my life super easy

and before calling it a night I got all the lines ran from the block to the turbo.



just have a lot of questions about the external wastegate. never worked with these before so I'm not exactly sure what to do with all these springs it came with. which one do I run? do I have to take it apart and swap the one already in there? and I noticed ports for h2o and air (I think it said), what do I do with those? also do i put vaccuum to the top? wastegate noob over here... I know.


I'm going to try to overnight my tt manifold, get that all situated. still got some odds and ends I need to pick up before I can completely finish putting everything together. I'd say I'm a week out from turning the key! YES! (:

[Cryser]

Your wastegate set up is going to be based on how your planning to be boost control.

Are you using N75, EBC, MBC? if EBC which EBC?

['04JettaGli]

Looks awesome man, looks like a blast too. You stationed in WA? Can't wait to see the rest fall into place!

[18T_BT]

Sweet man, for the record, you can use a 8mm (i believe) allen key to REMOVE the poly drive bolts, but not reinstall them. For future reference for other people really, seeing as you have the tool now

[a4e3y5]

just have a lot of questions about the external wastegate. never worked with these before so I'm not exactly sure what to do with all these springs it came with. which one do I run? Most of the time they come with the 14.5 psi spring, but you may want to double ck with Arnold. If you want to run a higher one, go to the tial page and you'll find the code for the colors do I have to take it apart and swap the one already in there?only if you want to run a stiffer spring and I noticed ports for h2o and air (I think it said), what do I do with those? also do i put vaccuum to the top? wastegate noob over here... I know. It has two ports...top and bottom. If you run a manual boost controller u will use the bottom one. If you run an electronic boost controller u will use the top one.


I'm going to try to overnight my tt manifold, get that all situated. still got some odds and ends I need to pick up before I can completely finish putting everything together. I'd say I'm a week out from turning the key! YES! (:

On a side note...I remember when doing my build.....good times !

[jstnGTI]

so, a simple reference to the instructions supplied with the wastegate informs me I just run a vacuum line from the IM -> mbc and then mbc-> WG. thought it was more complicated than that. I still haven't chosen an mbc to go with. suggestions?



please tell me if I misenterprated the drawing.

[formerly silveratljetta]

I have a simple aluminum ball and spring MBC if u want it PM me

[a4e3y5]

Any ball n spring will do....blox, turbosmart, hallman etc. If you want to go fancier you can go dual stage mbc. It gives the option to run lo boost n with the touch of a button hi boost. And yes, mani to mbc to wastegate.

Sent from te lo mande desde mi cel!

[jstnGTI]

been working working working so all I have left is the parts I don't have. Trying to get back on the road and enjoy this bad boy.

in no particular order:

got my TIP mocked up and mounted.

cleaned up my valve cover after that picture was taken.

got a fram (lol) oil filter today and filled it with ND30, also poured about two quarts over the cams and chain before I torqued down my valve cover.

should I put more? or prime my pump before start up and THEN add more? is two enough before I start priming?

I started bolting on my accessories; PS pump, alternator, A/C, accessory belt.

I chise to omit this brace of the oem IM because I'm going to be using a TT manifold.

so instead of bottoming out the bolt, I chiseled this washer/spacer/whatever off and everything was good (:

also started setting up my WG (thanks guys).

plugged all side vacuum ports except the one I'm using and the one above the barb there and I'm venting to atmosphere on the top. Re-used some vacuum line heat shield material from the old turbo.

called it a night.

[mk4boost]

doing werk man... everything is coming along great

[a4e3y5]

Coming along nicely...kudos to you! Did the same IC kit using the TT mani n it works nicely. Looking forward to dyno numbers in the near future. In the meantime, keep enjoying the build!

[18T_BT]

Looking good! See if you can run the oil feed line a little bit further away from the exhaust mani