Rolling with Pebbles

[hiho]

Pebbles got turbo'd. Our daily driver is a 1.6TD! That is until my girl gets home tonight in her shiny new reliable quiet safe clean rust free red 2009 Polo TDI. Then it becomes a true project car!

I installed a factory TD motor and gearbox that I pinched from a car I brought over from adelaide late last year. It has been a bit of a headache since installing it and the long felt feeling of reliability disappeared....






It doesnt start on cold mornings without a little help. I suspect a thicker than required head gasket has been installed..... Or the timing is off

THe flywheel has no TDC mark. I cant check the cam or injector timing......

Lots of minor water leaks

Huge gearbox oil leak.... Mangled seal carrier

New seal carrier installed

New seal installed

Flange going back on


I'll replace this box with an AMC Toledo box in a couple of weekends. It has the larger input shaft, 210mm clutch and 100mm flanges. Should be good for whatever i squeeze from the TD

I also got paranoid about the intermediate shaft bearing. The bearing usually never wears out on a petrol motor. But with the IP and cam to drive, and with some people overtightening the belt due to concern of piston/valve contact due to a skipped tooth, the bearing at the pulley end can wear prematurely in a diesel. I believe that it should be inspected when changing the timing belt. Mine was ok so i didnt replace it. Apparently you can tap the old one sideways with a punch (put a rag in there to catch it so it doesnt end up in the sump) and remove it then install the new bearing using the intermediate shaft as a guide.

With the new flywheel (complete with TDC marking), egt gauge and 2.5" exhaust I should be able to start tuning!!!

[gldgti]

show us yer exhaust!

[Preen59]

Nice work.

Just advance the injector timing dude. It won't hurt.

[hiho]

2.5 is the rusty sections top left

I am not worried about the ip timing so much as the cam timing. When i swap the gearbox i'll fit a 210mm flywheel with a TDC mark on it!

[gldgti]

hehe, i spy a turbo outlet flange with a bit of 2.5" pipe on it.

have you been driving it around with no exhaust?

[hiho]

Nah, its got the stock downpipe and a fairly ordinary 2" system on it at present. Im eyeing off some mig welders on ebay - once in hand I will complete what you've started with the turbo flange and install the 2.5" system!

Loving the missus' Polo TDI!

[hiho]

I cant believe this car is still my daily driver.

[Preen59]

Updates??

[hiho]

I pulled the carpets and soundproofing (PITA) to check the floors and brake lines. There was surface rust in the pockets formed by the body deadener. I brushed it off with a wire wheel and fish oiled the floors before putting the car back together.





I also reinstalled the original springs as the king springs are too stiff for regular dirt road use. With the rear ARB it still turns in nicely but has a fair amount of roll. I think I'll reinstall the rear king springs with some sort of spacer to level the car with the front std springs. This should return the body roll to what I prefer....

Otherwise this car just gets me about. It has a sweet spot between 100 and 140km/h in 5th which makes overtaking a sinch.

[GLDoldcoot]

Hey this looks like my daily! Its done 550 000km or so, and is called Gonzo [the colour is Mexico beige]. I drive it 100km/day on rough roads with standard springs, but I made the top rear spring cups deeper and installed rubber washers in them to pack up the rear suspension. I fitted a turbo to the original 1500 diesel about two years ago and it goes very well with the five speed gearbox. Needs new rings though.
Good luck with Pebbles


Who says you cant fit a turbo to a 1500!

Cheers
Rob