Turbo Diesel Cabriolet Project (with head porting pics)

[Jarred]

loving it!

good work on the alt bracket mods too!

[GoLfMan]

nice work Aydan!

[Greg Roles]

I am real jealous of how nice the plumbing is on your setup, my TDI had so much crap in the way!

That intetcooler fits a treat, you going to drill some holes in the bumper?

Looks like a nicely setup system, should flow bloody well!

[gldgti]

Thanks for the encouragement fellas!

I am real jealous of how nice the plumbing is on your setup, my TDI had so much crap in the way!

That intetcooler fits a treat, you going to drill some holes in the bumper?

Looks like a nicely setup system, should flow bloody well!

I'm not going to make any mods to the bumper/support panel as it stands at the moment.... its kind of a wait and see thing. For the purpose of the car, being my wifes car primarily and not for track work etc, even if the intercooler doesnt work at peak efficiency 100% of the time, I don't think we'll notice. I guess the main thing is that it can cool off between boost spikes.... rather than it being able to cool well all the time.

All the intake piping is SS mandrel bends apart from the silicone you can see, so yeah it shoud flow pretty well - probably a lot better than the setup I had on the mk3 (lessons learned )

The main restriction as I see it (apart from the turbocharger) is the airbox - its std mk1 fair which has a decent sized filter element but only has a 2" outlet. I did get an airbox from a '05 lantra that looked like it would fit but its very tight. Actually, I reckon the airbox from a late golf/octy/caddy/jetta diesel (all the same as far as I can tell) looks about the same external dimensions as the mk1 box I fitted in there, so that might be a good upgrade option.


I almost forgot - I managed to drive it into my garage from the lawn tonight.... after last night shenanigans I decided what it needed to run was a bit of fuel pressure to the pump (since its own lift pump doesnt seem to be working).

So, cue bike pump attached to the fuel return line, sitting next to me in the passenger seat, I pumped it up to a couple of psi (that is the fuel tank ) and started her up and sure enough it runs like a beauty! ofcourse, with only limited pressure, its got bugger all advance so it will only rev up to about 2000rpm but it was plenty enough to get me where i needed to go and I'm pleased to say the engine starts and runs sweetly - I even managed a few psi of boost

That means the injector pump will be coming out tomorrow for a rebuild ahh well, could be worse.

[gldgti]

update - car is almost registered

[gldgti]

Bit of an update for those interested:

> Got all the wiring sorted in the engine bay
> Fixed the injector pump. Took it completely apart no less than 3 times!
> Installed boost, oil pressure and EGT gauges
> Had to retorque the nut holding the oil coole onto the filter housing - after it had seated a bit it started pouring out oil everythwere.
> still got to sort a small leak from the sump gasket... this is annoying, it was a brand new gasket with the baffles but I can't figure whats wrong so tonight I drop the sump and am replacingthe gasket with a TDI (non baffled) gasket.
> Boost set to 8psi ( ) until I can put a couple of thousand km's on the new bearings and get all the bugs ironed out
> gearbox and linkages work great!
> intercooler works great so far!


So how does it drive? Well keeping in mind its tuned totally smoke free, and only running 8psi, its still about twice as fast as the 1.5D (feels like!!!) and its REAL quick off the line! obviously the long runner intake is doing its job nicely!

I gotta say the strangest thing is the sound it makes - its unlike any other golf i've ever driven. kind of growls, huffs and whistles all at the same time - quite strange but kind of cool... I guess?

Anyway, hopefully rego tomorrow!

[gldgti]

UPDATE

Further to chasing the oil leak, I discovered last night it is coming from the only oil seal I did not replace during the rebuild - the intermediate shaft seal!

So thats the job for the weekend!

[Preen59]

Way to go, dude!

If you had have told me about the seal earlier I could have mailed you a couple. I've got them coming out my ears. FYI for people that don't know, the seal is the same as the 8v camshaft seal and same on most, if not all models as far as I know.

[gldgti]

Just for added complication, I replaced the intermediate shaft oil seal but realised it wasnt leaking from the seal, but from the IM shaft retaining flange O-ring seal.... why? Because when I dismantled the engine and pressure washed the block, I lost the O-ring and never replaced it - WHOOPS!

I fixed it all up and she's running like a trooper and not a leak in sight, its about the cleanest engine I've ever had in a VW bar none (not even the SKODA!)

Got the rego inspection passed this afternoon, so it'll be road legal tomorrow!

This was the pump for the 1Y engine apart:

Some corrosion on the cam plate....


I had to re-use the plate but it was easily cleaned up - I used some fine valve grinding paste and the little rubber wheel for my dremel to buff the cam_plate smooth. I'd say this method would be good for any injector pump parts..... speaking of which, I'm pretty adept and IP repairs now so if anyone needs any help, let me know.

These parts are 2 pump heads for the VE pump - the smaller plunger is from the 1Y pump,
it has a 9mm plunger (less fuel). The big one is from a TDI pump - its a 12mm plunger - that equals LOTS more fuel - so much infact, when I tried it (of course I tried it!) I couldnt get it to idel without smoking a heap. Sounded a bit like one of those diesel drag cars or a pulling tractor, and I imagine I could have melted pistons/turbo's in no time at all! Anyway, since this is a cruiser really the big pump head is going in the parts bin for my twincharge project, should give all the fuel I need

The completed engine bay:


Cabby with a new heart


Vid for a bit of noise!
http://www.youtube.com/watch?v=5cHeEI2kRks

[Transporter]

Nice job mate.