Author Topic: Golf Mk3 TD pics, EGT probe, turbo return...pics (Read 8035 times)

DieselMonkey · « **on:** August 30, 2005, 04:14:16 pm »

Guys,

Thought I would post some images of my Golf project, re-spray was completed back in feb, since then its just been a steady job of building the car as i've always wanted a mk3. Minus the roof aerial, spoiler, rear wiper and plastic arch flares.

Motor was a 1.9L D (1Y), since been fitted with a new Garrett GT15, mk3 TDi downpipe, mk3 TDi intercooler, AAZ pump with 1.6 GTD boost pin and adjust. lid :twisted: , 1.6L GTD injectors shimmed to 160 bar, 1Y injector lines (make fuel adjustments v. hard), new 1Y / AAZ crank sprocket and TDi bolt + high strength loctite. 1.6L GTD sump with drainback. EGR system deleted, EGT probe in place. Intake manifold - lower AAZ, top part from 1.6L GTD Golf mk2. New genuine VAG glow plugs, t'belt, tensioner, alt belt, PAS belt. MANN W940/25 and Mobil 1 Delvac 1. Self made boost controller, wastegate actuator bracket and EGT probe plate.

Was started for the first time in 6 months on sat afternoon

, however, still no 100mm GTi driveshafts (hard to find a good pair)

.

Is this location for the EGT probe just as accurate as it would be before entering the turbo or is there going to be a considerable difference ?

Hope its of some interest. Regards, DM

kynetx · « **Reply #1 on:** August 30, 2005, 08:03:40 pm »

Man that's pretty. Nice work.

To regurgitate what I've read, the EGT guage is supposed to go before the turbo to ensure more consistent readings. If that's reasonably accurate, that's an easy way to do it!

vwmike · « **Reply #2 on:** August 30, 2005, 08:58:06 pm »

Quote from: "kynetx"

Man that's pretty. Nice work.

To regurgitate what I've read, the EGT guage is supposed to go before the turbo to ensure more consistent readings. If that's reasonably accurate, that's an easy way to do it!

Generally I've read/heard that it is supposed to be about 1" from the exhaust port, but I would think that so long as it is before the turbine it should be fairly accurate.

Here is mine -

I couldn't get it any closer to the port because of the length of the probe. That corner was where the most room was available.

malone · « **Reply #3 on:** August 30, 2005, 09:28:04 pm »

Perhaps for a more accurate average reading, the probe should be in the centre of the exhaust stream coming from all ports. The difference is probably neglible though.

Your whole car looks super clean!

vwmike · « **Reply #4 on:** August 30, 2005, 10:01:56 pm »

Usually #1 has the most cooling issues so the first sign of a problem should come from there. That was my reasoning.

ricosuave · « **Reply #5 on:** August 30, 2005, 10:21:06 pm »

damn that looks good!

DieselMonkey · « **Reply #6 on:** August 31, 2005, 01:29:49 am »

Thanks for the commnets guys.

vwmike, i was always told that the rear most cylinder from the water pump was the hottest running, most problematic and the first to seize in an over heat situation.

The mk2 GTD i rebuilt, cylinders 2 & 3 where badly scored because the injectors where leaking before i bought it. I also have a 1.6L GTD block in the yard with the piston of cylinder 4 badly melted away, just where the combustion would reach the piston from the pre-chamber, dont know why only this piston melted and the bores where lightly scuffed too. probably injectors again.

It is quite a long probe isnt it. My probe looks to be the same as yours, i got mine from 42 Draft Designs in Maryland.

regards, DM

vwmike · « **Reply #7 on:** August 31, 2005, 02:17:33 am »

I had an aba block with a melted #1 when my intercooler heat soaked (17 psi on 92 octane pump gas can catch up with you on the dyno). I had also heard #1 had the most cooling issues...either way it doesn't really matter. Anywhere in the manifold should probably be close enough and good enough for tuning purposes. My pyrometer is a VDO unit from summitracing.com

Maarten · « **Reply #8 on:** September 05, 2005, 02:01:00 pm »

Your engine setup looks a lot like mine

but a lot cleaner :shock:

The probe should be in the gasstream so your setup is clean and simple but not ideal.

dieselweasel · « **Reply #9 on:** September 05, 2005, 03:36:27 pm »

Maarten · « **Reply #10 on:** September 07, 2005, 03:29:47 am »

The input heat is crucial for the turbo, temps above 850/900 deg C for an extended period of time can kill you turbo!

Leaks in the intake or exhaust can be spotted with your ears/fingers so I think pre-turbo is the best spot for the EGT probe

VWRacer · « **Reply #11 on:** September 07, 2005, 10:06:49 am »

Don't worry about getting it perfect DM, unless you are racing the car a lot. What you have is (aside from commendable pride of ownership and workmanship!) will work fine for any normal driving. Keep the progress reports coming!

Cheesetoast · « **Reply #12 on:** September 07, 2005, 10:45:42 pm »

looking Hot, few questions for my own edumication

what's the advantage of the mk3 TDI downpipe?
How are the 1.6td injectors better than the 1.9?
whats the adjutable lid on the fuel pump, how's that work, where do you get it?

are you going to intercool it? I have a mk3 tdi intercooler on my 93 1.9td and it works quite well

DieselMonkey · « **Reply #13 on:** September 08, 2005, 07:43:49 am »

Guys,

Sorry to reply only now, some reason I didnt receive an e-mail to say the topic had a new reply, but anyway....

Cheesetoast... the mk3 TDI down pipe was needed because the AAZ uses a KKK K03 (inc. several others) that are mounted above or at head level, rather than down the back of the block. It was either use a TDI (mk3) downpipe, or make one to suit.

I'm not sure why the 1.6GTD injectors are better than 1.9L 2 stage ones. They both crack at the same pressure (155 bar), mine are shimmed to 160 bar, but single stage. The 1.6GTD's give better low end power, and the 1.9's better top end power.

The adjustable lid was on the 1.6 GTD's. It allows for adjustment of the boost pin, by adjusting the 'torx' at the top of the lid. Its a pre-load device, so if you screw it down, the boost pin will always be fuelling slightly more up to the point of boost arrival. Without a lot of boost (+1.2 bar),... dont adjust too much, or you're just wasting fuel and creating a lot of smoke. You will get this lid, and the boost pin to match it, from many Bosch VE pumps. Renaults, Peutgoets, Fords, VWs, Audis, etc...

I have one from a 2.1L TD Renault, and the design of the boost pin is quite more extreme than the 1.6L GTD's. I have several boost pins, but only one lid. I could get you a matching lid this weekend if you need, let me know.

I'm using a std. MK3 Golf TDi intercooler, with my own manufactured 316 SS tubing. Should get the pipes made in the next few weeks.

Any pics of your motor ?

Regards, DM

Vento · « **Reply #14 on:** September 08, 2005, 11:50:47 am »

Hi DieselMonkey,

I live in the UK and have a 94 Vento with AAZ engine. I have managed to get my hands on a G60 Intercooler but am struggling to find somewhere that does or will make up some pipework for it? Where did you get your pipe work from? Have you any pics of the intercooler installed?

Good Luck with the project! It looks excellent