1.9TD Coupe Project

[RadoTD]

Is that an aftermarket or OEM oil temp gauge? That sounds absurdly high for these engines. I had a GTI with an MFA and my oil temp was showing some funky yet almost believable numbers. It ended up being a voltage regulator in the cluster itself. Turning my lights on/off changed my oil temp by 20deg C

[zagarus]

it's an autometer oil temp gauge and sensor. 

[Big Daddy Roth]

So what are you doing about the breather system?

[vanbcguy]

How are you liking the AWIC?

[zagarus]

I'll find out soon enough, just got it working yesterday after waiting for some new fittings due to a leak.   EGT's seem to be a lot cooler now.

[zagarus]

AWIC seems to help alot in keeping the EGTS low. They do climb high when i really romp on the pedal but they drop even faster.   I also got to eager and installed my boost controller the other night and left it where it was on my old car...25psi.  All I can say is holy smokes!!!!!!!!   Less smoke, EGTs are down a lot, the sound is incredible and the pull is nuts!!!  As for cruising on the highway at 100kph on level ground EGTs are about 550F, boost is between 1-2psi, oil temps roughly around the 220F mark (Still trying to get them down). This car pulls just as hard uphill, its crazy!!!!!

I'll make a video tonight of some pulls and i'll have a few more pictures to show after tonight.  I am very happy with this car 

[vanbcguy]

Cool beans... did you end up running a fan on the AWIC radiator?  I'd love to see pics of some of your plumbing / pump / reservoir etc if you have them....

[zagarus]

Well it's been awhile since I got to play around with the car so here is a mini update:

March 5th I pulled the car out of hibernation so I could move it to its new home



Upon arrival I immediately got busy



Issues I needed to resolve include but not limited to:

- Oil pan gasket leaks
- Valve cover leaks
- Oil flange leaks
- More F$^#ing oil leaks
- Broken pressure plate (too much torque + ***ty sachs quality = BOOM!)
- Redo AWIC piping (had a couple pinches that killed water flow)
- Attempt to solve timing belt shaving issue (hopefully was just the tension pulley)
- Install bump steer kit
- Install oil filter relocate kit and larger oil cooler
- Get injectors rebuilt with new nozzles to 155bar
- And for fun bought a Nardi/Personal wheel with Nothelle horn button

I haven't been taking any pictures ( i really should have) but here is the new oil cooler mounted.  3/4 of it is behind the bumper but I need to find a slim fan to help cool that area. Air still has plenty of room to flow in front of the whole thing so we will see how it performs.



Here it is as of yesterday while my buddy installs his Westy front end with homemade badgeless grille



Here it is as of today back on the ground



Annnnnd this is me getting into the F1 spirit with the Malaysian Gran Prix happening this weekend



Goal is to have it running (at this point will be as soon as the rest of the parts I ordered arrive) before Spring Unsprung down in Vancouver.  Cruise test!!!

[zagarus]

Got the car fired up today, once again very loud, might have to check my timing again (ugh). In other news the car doesn't move! How excited am I?  Oh about this excited...    I can put it in first, release the clutch and car just idles away, looks like tomorrow will be spent pulling the tranny from underneath the car (not looking forward to that again).  I'm hoping it's just the wrong clutch spline or something because nothing has changed since I took it apart except for new centerforce PP and clutch.   Why would it be the wrong clutch I wonder? Well that's what I'm going to find out and then I'll know if I'm to blame, or there is someone else I can get mad at lol.  Will take pictures tomorrow.

[starrd]

Hi Zargus,  Just wondering how you resolved your timing belt getting shaved?  Do you know there is a service bulletin regarding this issue?  It involves loosening the 3 bolts for the injection pump bracket and pushing one way or the other depending on which way the belt is running away.  I can send you a copy if you like - let me know.  Also make sure you tension the belt correctly - if you over tighten it, you will take out your injection pump bushing.  I use the proper tool to tension my belt now after I learned the hard way!

-Don

[zagarus]

Yes a link to the shaved belt info would be much appreciated!   Also found out the transmission problem...Wrong clutch.  Got a 28spline 16v clutch instead of a 24spline 8v clutch.  Both are 210mm but the 8v is a 13/16 center and the 16v is a 7/8 center.  My bad for not doing the proper research but I assumed they were the same because my old Sachs kit was labelled as a 16V HD upgrade.  Bastards.

And so there is no confusion I am running the 8V gasser flywheel from the original engine from the coupe.

[zagarus]

Finally out and driving, man this thing is a gokart!!!  Looks like I have all the leaks under control, haven't spotted anything as of late.  Oh ya and oil temps and coolant temps are waaaaaaaaaaaaaay down!!!  Unbelieveably cool actually, will be perfect when the hotter summer temps hit I'm so happy!!!

Anyways spur of the moment pictures.  Only issue still is the radiator for my AWIC actually got buggered up during winter so it's currently not flowing any water until replacement arrives.  No bigs I just won't hit 25psi until then lol, but 15 is still fine

[DJPyro]

I love this car so much.

[macka]

  stylin', probably one of my all time favourite mark 2's

[zagarus]

Took the car on a little hwy roadtrip north to Clearwater, oil temps were 185F on level ground cruising at 110kph and coolant temps were around 165F.  Thats ~80C for oil and `73C for coolant.  Looks like I'm ready for the hot summer days