Question about pistons for the VW Crafter 2.5 CR TDI 163 hp

Hi!

Perhaps one of you has already handled the pistons from the 2.5 CR TDI engine in the VW Crafter. I need some information about these pistons, especially regarding the oil jet cooling system. I'm not sure if the opening to the oil channels in the piston is on the same side as it is in the 2.0 PD TDI pistons.

"Why this question? The pistons would be an ideal basis for a conversion of a PD TDI engine, as they have a compression ratio of 16.8:1 from the factory. Furthermore, the 2.5 CR TDI engines are 2-valve designs and have the injector mounted at a 25-degree angle in the cylinder head." Therefore, potential candidates and, from my perspective, BGW/BHW pistons would be preferable.

It would be great if someone could offer some helpful information about the oil spray cooling system for the pistons!

Regards,

Fabian.

Short update:

I've made some progress with my research - the pistons in the Crafter engines with 100 kW and 120 kW are (unfortunately) supplied with oil injection from the "other" side. This means that using those pistons in an 8V PD TDI engine is initially out of the question - unless I find a relatively simple way to reroute the oil injection cooling or, alternatively, supply the pistons from both sides. However, the piston doesn't have the necessary hole on one side, and I'm having a bit of trouble drilling the holes in the pistons.

Regards,

Fabian.

Do these things have an oil channel in the piston? O_O ... So, no more just filling it from the bottom?


pictures?

Yes, they have a cannula with 2 holes.

I have added the pictures from my post below as attachments, thanks to the tips

You can clearly see the drill holes. The pistons also have a 26mm piston pin; I jokingly tried fitting them onto my Panchi connecting rods, and they fit perfectly. I'm currently working on a solution for the incorrect positioning of the oil cooling holes...

Regards,

Fabian.

Hi Fabi!

Thank you very much for the feedback and especially the pictures!!!

Now we can all understand what is meant and how it is being asked.

I have just one small request for you:
Please upload the images to the "Upload" section of the forum and then link them from that location to this post.
Thank you!

Best regards from Munich!

He can also upload it directly . It's simpler and prevents topics from being fragmented if the corresponding links stop working after a few weeks...

Okay, I'll try it now with "Add attachment" .

and where should the drilling for the DIY motor be located now? On the same side as the piston pin, but on the other side of the piston?

'By the way, that's a terrible lump... What's the weight of the whole thing, including the bolts and rings?'

I've attached a picture below showing a BJM piston (Crafter) on the left and a BMM piston (Touran) on the right. You can see a round opening in the skirt where the oil jet fits. On the left piston, this opening is located in the lower right corner; on the right piston, it's in the upper right corner. Both pistons are oriented the same way, with the piston bowl and valve recesses on the same side.

The pistons weigh 851g including the pins and rings, with the pin alone weighing 203g. But the other pistons weigh the same . However, I have counteracted this weight with lighter Panchi-H shank connecting rods.

You could certainly contact MAHLE directly and ask them what they have to say about it; maybe they have a suitable idea for you.

'Do you happen to have an old piston that I could use?' If that's a 'ring' that's completely open in both directions, we could potentially fill the holes and re-drill them. But if it's only a half-ring, it's probably not going to work out well.

Stummel wrote:

Do you happen to have an old piston that I could use for cutting?

If that's a "ring" that's completely open in both directions, we could fill the holes and re-drill them... but if it's only a half-ring, it looks bad.
However, he also needs the 'groove' in the cylinder liner. In my opinion, there are two mountable versions of the oil injection cooling system, and the one that injects oil in the middle shouldn't require any modifications to the cylinder liner. The only question is whether it will work otherwise.

Regarding drills, I wouldn't worry too much, considering the intricate designs that can withstand in 2-stroke engines... with power outputs of 200 horsepower per liter or even higher.

Best regards, Rainer.

Well, the 2-stroke engine achieves its power through high RPM, whereas other things are more important for a slow-running, high-torque engine like a diesel.


'If there's a notch in the shirt, you can file it down at home. Using a piece of cardboard as a template, you can get it fairly accurate with a little measuring and adjusting.'


If the oil channel in the piston isn't perfectly round, and you drill it open randomly, there's a high probability that the piston will overheat and melt, as the oil flow will be disrupted and cause localized hot spots.

@Deus violentia: I already inquired, but the effort involved in getting a set of pistons isn't worth it – or it would be incredibly expensive.

@Stummel: No, I don't have any old pistons to cut open - at least, not from a Crafter . I'm pretty sure there's a full ring in the piston and not just half a ring, but we'll figure that out. If necessary, the piston will be X-rayed.

"@dieselschrauber: The groove would be machined in using a CNC milling machine, just like the "new" oil holes, and both would be located exactly at the same position as on the OEM pistons. What are the two variants of oil jet cooling? I only know the variants like in the Crafter vs. 2.0 PD TDI. I'm not familiar with a central design; where would the oil jet nozzle be mounted in the block? At the same locations as "normal"? " Do you perhaps have any medical conditions where this is the case?

Regards,

Fabian.

Quote:

Are there any of you with MKB who experience this?

It should be an AJM (1.9 PD) engine. Unfortunately, I don't have the details about how to attach the oil spray nozzles readily available.

Fab176 wrote:

What are the 2 variants of jet oil cooling?

There is an older version where the nozzle is angled, causing the oil jet to perform a wiping motion across the piston head during the stroke. This design was used in engines without a water jacket, such as the AHF, AJM, and some AUY models, among others.
The new version uses spray nozzles that direct the oil jet into the cooling channel opening, regardless of the piston position, similar to almost all cooling channel pistons.
"Both pistons require recesses in their skirts, and the nozzle attachment method is the same for both."