G-Teched my 1.6TD - Baseline Runs

[malone]

Dave, I have good news about the PD150 VNT-17 turbo. Last night I saw you on MSN, but you went offline before I could hit "send", doh!

I'm at work and I don't have your email address (it's not in your user profile either). I'll send an email when I get home tonight.

There are a few VNT-17s that appear to have less than 1,000km on them. Two of them are rust-free on the exhaust manifold!!

Cheers,
Mark

[malone]

Quick updates:

1) Several days ago I played with the idle screws and it idles nicely now. The rev no longer drops below 910RPM.

2) Starting yesterday (and suddenly), cold starting became more difficult with at least 15 (!!) cranks required to start. Starts fine if the engine's warm. I will check the glow plugs tonight.

3) Giles recently finished rebuilding my 1.6TD pump. Payment is getting sorted and I'm expecting to receive the pump sometime next week. I can't wait

4) Depending on how well the car performs off-boost (& light smoke) with the new pump + injectors, we may proceed to replace my stock Garrett turbo with a brand new GT20 turbo (0.53 A/R) I already have sitting around.

[malone]

I'm pleased to receive my pump from Giles@Superior Fuel Injection today. It looks brand spankin' new



However I have some not-so-good news:

I intended to sell my MK3 1997 Golf CL (1.8L 8v) after I bought the Jetta 1.6TD. The Golf has been very reliable in the 4.5 years I've owned it, until a few days ago, just as I was ready to start selling it. It suddenly developed a fuel leak in the fuel injector/throttle plate section. I'm currently getting 375km (225miles?) @ approximately 48L. Normally it should be 550 to 600km. Power is also greatly reduced with a shudder.

The fuel leak didn't seem like a big deal to fix, until I found the price to replace the defective part, which was much more expensive than I thoughtt!! The small parts inside cannot be ordered or replaced individually. The progress for the Jetta 1.6TD is stalled for now until the Golf's fixed.

I just realized that swapping in another engine for the Golf will be better than fixing the fuel leak and keeping the 1.8L 8v. How about a 2.0L 8v ABA? Nope. A 2.0L 9a 16v? Nah. A 1.6TD? Sounds right

A 1.9TD might be nice but it's not necessary and I'd rather save some money. The 1.9 also doesn't seem to be a big revver.

So Jose @ JS Performance will help swap a TD into the Golf. We're hoping to complete it within a week.

Pros for switching to my 2 door MK3 Golf:

* There are no 2 door MK3 Golf diesels sold in North America, yet I've always wanted one. So it would be unique.

* More refined. I already have another MK2 Jetta with a TDI swap. It's stripped to the bone and will have plexiglass windows. I don't feel like having two MK2 Jettas

* I will likely pick up a 1986+ 1.6TD with a hydraulic head. This means no routine valve adjustments and the ability to fit a 1.9TD head.

* I've had the Golf for 4.5 years. I'm still attached to the car.

* More engine bay room.

Cons for switching to my 2 door MK3 Golf:

* 200-300lbs heavier. That fact bothers me a little bit because it will affect how quickly the car moves. However, a little weight reduction can fix that.

* Re-do the exhaust system :? However, some custom exhaust pieces from the Jetta may be re-used for the Golf, especially the straight pipes.

* The Golf's dashboard does not have the cold-start pull. However, I have two spare MK2 diesel dashboards sitting in my garage. I can remove one of cold-start pulls and drill it into the Golf's dashboard.

I will sell the Terra Cotta red Jetta 1.6TD after the basic Golf swap is complete & functional.

This is getting pretty tense!

The Giles-modified pump & Smog's 160bar GTD injectors will go into the Golf. I will post comments once it runs.

[935racer]

Hey mark, why not buy my 1.6 hydro thats in my caddy? Than we can put a tdi with a 6speed in there :twisted:

[DVST8R]

Hey mark, why not buy my 1.6 hydro thats in my caddy? Than we can put a tdi with a 6speed in there :twisted:

Now that's what I'm talking about!  :twisted:

[malone]

Hey mark, why not buy my 1.6 hydro thats in my caddy? Than we can put a tdi with a 6speed in there :twisted:

You're my saviour dude! I was getting a little worried. I replied to your PM.

Hey Brett, I'm not sure if you got my MSN this morning but Dave and I are gonna pull the 8v tranny this evening for you.

Any suggestions on packaging for shipping the tranny? I'll ship later tonight if Greyhound is still open, or tomorrow morning.

[Staley]

malone,
have you installed the pump Giles rebuilt for you yet?
I sent him one to rebuild also.. and I can't wait to get it back!

[malone]

malone,
have you installed the pump Giles rebuilt for you yet?
I sent him one to rebuild also.. and I can't wait to get it back!

I wish! My MK3 Golf will be receiving a 1.6TD swap and the Giles pump will go into that car. The swap isn't completed. I will post results once the 1.6TD + pump are running.

So far I'm really happy with the way the pump looks and Giles's service was flawless.

DVST8R's (Brett's) replacement transmission was pulled Friday evening. Major thanks to 935racer (Dave) and his buddy for the help. It took a good three hours due to a couple stripped bolts on both driveshafts.


The packaging was done on the next day. My Golf's pictured as well.





Packed up and ready for shipment to Edmonton, AB. I will choose Greyhound's 1 day shipping (bus) if the price's reasonble.


Tomorrow (Monday May 23) the Golf's 1.8L 8v gas engine will be removed. On the following Wednesday or Thursday Dave's 1991 hyd lifter 1.6TD will be dropped in.  

[92A2VWJTD]

You boys are certainly not pissing around or shying away from the good fight. Nice to see such all encompassing projects tackled with no delay and thanks for keeping us all informed. I'm learning lots! Keep it up.
935racer - Good luck with the 6spd TDI Caddy. Thats sure to kick ass!

[935racer]

Yeah I am stoked about putting a tdi in my truck, but first I have to go pullt he 1.6. I am gonna go do that right now, hopefully someopne willc ome join so I am not stuck doing a loaner engine pull. I'll try to drop the engine onff at joses tomorrow if possible mark. If you want I can help install it as well if it will help you out. If you want to come out tonight you are more than welcome to mark, but not really nessesary cause Is tillneed to put some new intermediate shaft races int he engine before you start toying with it so that you have premium oil pressur ewith that new oil pump I just put in there.

[DVST8R]

I would be there if I could  I will be there for the puting in and taking out and puting in and taking out..... of the TDI motor . Hope it goes smoother then the tranny pull.

[malone]

Dave making a hoist to lift the engine.








Everything (i.e. coolant lines, etc.) was disconnected from the engine at this point.


... and the 1.6TD engine's out! The block will be chemical cleaned / powdercoated, but that's for later.


The Garrett turbo is in flawless shape (hardly any play, blades look new) but I won't be keeping it for long.


A couple Jettas parked outside.




The beater 16v Turbo just kidding Dave. Anyway, this is his temporary car until his Caddy receives an euro TDI implant.


Exactly what a 16vT is good for; grocery getting Dave's taking my 1.6TD to his work to put in new intermediate shaft to improve oil flow to the head.


The 1.6TD will then be dropped off tomorrow in Abbotsford, BC, where my Golf sits. I'm hoping the 1.6TD > Golf swap will start tomorrow night or Friday night.

[935racer]

I just got back from dropping off the engine. Today I pulled the pan and oil cooler and t bel;t and such so That I could pull out the old intemediate shaft. Popped off the clutch and took the frost plug out of the backside there. Once I had the shaft out I got a guy froma local machine shop witht he right puller to remove the old shaft races and install the new double plated durabond races. I made sure that the holes in the races were perfectly aligned and than reassembled the ngien witht he new water pump and oil pump. The oil pressure will now be as brand new. Having dissasembled a few diesel engines I find this a very commont thing that is overlooked. Even whent hese engines are rebuilt the stock races are often left in and gradually the plating wheres off and you slowly lose oil pressure. You will first notcie it at idle, than slowly through all rpm ranges you will be short on oil pressure. I'll try and get mark to take some pictures of the old races so you guys know what to look for. Now I just gotta geta tdi... and a 6 speed... :twisted:

[935racer]

Yeah the 16v turbo is just a grocery getter. actually this weekend I should be taking it off the road, I will be pulling the ngine and installing it in a buddys rabbit. The engien has megasquirt standalone fuel and spark management, and that huge spearco fmic, and a T3 super 60 turbo. bla bla. Can't wait to start messing with injection pumps and black smoke again.

[malone]

Golf 3, engine removed:


Left: 1.6TD. Right: Old 1.8L 8v.


I was really hoping to get the 1.6TD install started yesterday.. unfortunately it's gonna have to wait until Wednesday because of the shop's limited space/time :?. Anyway I'll continue posting updates.

The MK3 Golf will be partially stripped down to MK2 weight or less - 2,440lb maximum (wet)

Major thanks to Dave for helping me get the 1.6TD and keeping it in top shape. I owe ya; still working on getting the PD130 TDI from Finland for you.