Golf Mk3 TD pics, EGT probe, turbo return...pics

[Cheesetoast]

[Vento]

Thanks for the pic Cheesetoast. The problem I have got with the G60 intercooler is that is more square/box shaped and there isn't the room like there is for a flat one. May have to rethink my ideas and plans. Will stick a pic on if I can get one.

[DieselMonkey]

Vento,

I cant remember what a G60 intercooler looks like, but the standard mk3 TDi intercooler is behind the front bumper to the lower right, if looking straight on (on battery side).

Its not a bad intercooler, but not ideal. If i had the money, i would have had a custom one manufactured to go in front of the radiator. There is room for 2 different designs, but both would require custom pipe work.

If you can, post an image of the G60 intercooler. You might be able to use 1.9TDi piping or 1.6GTD pipes.

I personally prefer to buy stainless bends and straight pipe and weld it up myself. I dont own a Tig welder, but we have an excellent one in work that i use regularly for this sort of thing. You would be better having a custom set made to fit. An exhaust fabrication shop could do it also. Forget about getting it bent, those mandrel bending guys charge crazy money, in my part of the world anyway.

regards, DM

[DieselMonkey]

Cheesetoast,

You've got a similar set up to mine I can see.

Did you buy the car like this, or build it yourself ?

I can see it has a K03, TDi intercooler and fabricated pipes, a boost controller which looks to be situated in the cabin, or somewhere around the firewall, the TDi alternator and tensioning system (dont think the mk3 1Y and AAZ engines had this setup), and a pump that i'm not really sure about (well; it is a 1994 - 1995 Bosch VE). Is it from a Peugeot ? never seen one quite like it before.

Is that part of a wastegate actuator custom fitted to the top lid for some reason ? What function does it carry out ?

Bet it runs like a clock, what numbers do you think its making ?

Regards, DM.

[Cheesetoast]

I bought the car %100 stock, bought the intercooler with all the stock piping (this is important, mainly the piping from intercooler to up by the battery, hard to fabricate).  Jsperformance (jsperformance.com) did the intercooler piping, the bracket to the intake manifold had to be changed to 1.6td one to fit correctly.  Greddy profec II spec B boost controller on there, works well, going to be installed in my ashtray, but currently in the glove box.  Didn't change the altenator or tensioning system, afaik it's stock.  The pump is stock as well, not sure what you mean about the wastegate actuator, that on top of the pump where the boost pin goes? stock.

ran a 17.3 quarter at the track, that was with the boost controller adjusted for stock fueling, i forgot i had it set like this, probabyl will run slightly faster now.  gtech said 113 torque and 100hp if i rememebr right, i'll have to check up on that.

One problem i have sometimes is if i'm flooring it, near the upper rpm in second or third it will sometimes have a hesitation, like you let off the gas or fuelign isn't getting through, does it for a second or so. keep it floored and it recovers, doesnt' make any weird noises, just loses some power for a second.

Cheesetoast,

You've got a similar set up to mine I can see.

Did you buy the car like this, or build it yourself ?

I can see it has a K03, TDi intercooler and fabricated pipes, a boost controller which looks to be situated in the cabin, or somewhere around the firewall, the TDi alternator and tensioning system (dont think the mk3 1Y and AAZ engines had this setup), and a pump that i'm not really sure about (well; it is a 1994 - 1995 Bosch VE). Is it from a Peugeot ? never seen one quite like it before.

Is that part of a wastegate actuator custom fitted to the top lid for some reason ? What function does it carry out ?

Bet it runs like a clock, what numbers do you think its making ?

Regards, DM.

[DieselMonkey]

Cheesetoast,

I dont know if VW built Golf mk3's in the Belgium factory but maybe that has somthing to do with the pump. I've seen a lot of 1.9TD's and never come across that actuator device as bolted to the top lid of your pump (has a light red line running to it, possibly from the vacuum system). (could you tell me what its connected to, or appears to do?)

100 hp is good. How did you get to this figure ? Is it a stock AAZ motor with TDi intercooler and the Greddy boost controller ? Any extra fuelling ? What is smoke like ? peak boost pressure ?

That hesitation could be a few things. Slipping clutch (v. doubtful) but possibly a copper washer seal area drawing air, maybe a small leak back at the fuel filter (the plastic T peice - o ring - in the return line), lack of fuel, dirty fuel filter etc.... could even be a problem with the transfer (lift) pump in the injection pump.
 
I visited your website. A lot of good info there. Could you PM the part numbers for your front / rear bumpers and side markers some time if you get a chance and are able too. I'm thinking of fitting these, its a nice change to our Mk'3, i'd really appreciate it.

If you need a better boost pin (than stock AAZ) and, or, adjustable lid, I could get one sorted out for you.

Regards, DM

[DieselMonkey]

Cheesetoast,

I think i know what the actuator on the top of the pump is for.

I'm pretty sure it automatically increases fuelling if the air con is switched on at idle, so it will stay at 1000 rpm. Its been a long time since i've seen a 1.9L IDI TD with aircon !  

DM

[Cheesetoast]

Fueling screw is turned up a bit, i get smoke if i bog it and floor it, otherwise i don't see any.  Boost is 21psi peak.

Clutch isn't slipping, it's a brand new gti 8v clutch with 16v pressure plate and lightened 16v flywheel.

I recently replaced the plastic peice ontop of the fuel filter, washer as well.  i had bubbles in the lines, they have since disappeared, new filter too.

Car has 260,000km on it so maybe the pump is getting a bit tired.
going to put the 1.6 gtd injector nozzles in, i'll let u guys know how that goes.

My front/rear bumpers are OEM smooth top, i sanded the tops with 400 grit and used truck bed liner to get the textured look, matches very well with the stock textured side molding.

Glad you can get some info from my site, i used to have my full car specs, but since it was stolen, i removed all that for security.

Already got the better boost pin, thx.

Cheesetoast,

I dont know if VW built Golf mk3's in the Belgium factory but maybe that has somthing to do with the pump. I've seen a lot of 1.9TD's and never come across that actuator device as bolted to the top lid of your pump (has a light red line running to it, possibly from the vacuum system). (could you tell me what its connected to, or appears to do?)

100 hp is good. How did you get to this figure ? Is it a stock AAZ motor with TDi intercooler and the Greddy boost controller ? Any extra fuelling ? What is smoke like ? peak boost pressure ?

That hesitation could be a few things. Slipping clutch (v. doubtful) but possibly a copper washer seal area drawing air, maybe a small leak back at the fuel filter (the plastic T peice - o ring - in the return line), lack of fuel, dirty fuel filter etc.... could even be a problem with the transfer (lift) pump in the injection pump.
 
I visited your website. A lot of good info there. Could you PM the part numbers for your front / rear bumpers and side markers some time if you get a chance and are able too. I'm thinking of fitting these, its a nice change to our Mk'3, i'd really appreciate it.

If you need a better boost pin (than stock AAZ) and, or, adjustable lid, I could get one sorted out for you.

Regards, DM

[DieselMonkey]

A turbo wont run over speed if the wastegate is stuck open, and the only leak that could cause excessive temperatures would be an intake leak of charged air. To little air charge, not enought O2 to burn all the fuel and as a result, smoke and high exhaust temperatures.

Its unlikely that the VDO pyro will give quick enough results to make a difference anyway. There is a quicker reacting one, but the probe is known to fail much sooner.

DM