Winterization

[zozep]

Hey guys,

Recently had the intercooler plumbed in that I got off ebay... My post might be a bit unorganized, and long winded but bear with me.



Took some hacking but it's in. I've noticed since the install a few problems, hopefully someone can give me some ideas of where to start. One is smoke and a coolant level light blinking, the other is a strange vibration.

The pump is set by Giles for 20 ish pounds of boost (done last year) with an intercooler (metal HG, ARP Head Studs), in the hopes that the pump would regulate boost. The wastegate is deleted. I now hit 27-29 PSI at WOT without any problem, does it ever scream! I'm thinking of turning down the fueling abit for reliability, thoughts?

If the car is left for more than 48 hours without being turned on, it smokes one large cloud of white smoke, it then stops smoking (once warm). However the coolant level light in the dash blinks. So I back out of the driveway, and then reset the car and the light goes away. Check coolant levels, looks ok, might be a *little* low.

I live in Central Ontario, It has started getting colder consistantly now, mornings here are around 5- degrees celcius, (42-47Farenheit). The car starts with one crank everytime, but I am a bit worried about the white smoke I see if the car has sat for longer than 48 hours... I need reliability in the winter, it can drop down to -30 here quite quickly, last winter I had many problems of the car not being able to start, started fine on a block heater though.
Are there any things I should make sure to replace? Timing is set to 96, last checked about a year ago, injectors from Prothe, haven't had any problems with them, other than the fact that it looks like they "weep" a little.

My plans are, before the winter, to replace:
-Alternator
-fuel filter
-synth oil
-*maybe* injectors?
-another battery for higher capacity at 770cca?
-have compression checked?

Anything else I should refresh/check?

I will try and get a video of the rattling sound I get...only rattles at a certain RPM...Almost sounds like a washer that is loose, or an exhaust rattle, but just can't find it.


Here are closer pictures, sorry about the size. Comments about the install welcome as well please...

[zukgod1]

Routing looks good..

Wish I could have routed mine like that but the AC Condenser kinda gets in the way.

I believe White smoke is unburnt fuel.

Timing is set at?

[zozep]

Routing looks good..

Wish I could have routed mine like that but the AC Condenser kinda gets in the way.

I believe White smoke is unburnt fuel.

Timing is set at?

96 I believe... that was about a year ago now. Giles said there would be no need to advance the timing as there is plenty of "dynamic advancement"...or something like that.

[zukgod1]

Ok, what's it set at then?

[zozep]

 

96

0.96 mm

Thanks for the correction on this...very helpfull

[zozep]

Also, second engine picture.. the right side of the head looks like oil is leaking from the valve cover..although I have a rubber one, and its less than a year old.... Guess I should take care of that too...

[92EcoDiesel Jetta]

96

Is that the year? 

[zozep]

wow.. im having more luck on vortex, imagine that.

[zozep]

Ok, what's it set at then?

I'll have to get back to you with specifics... I really don't think it's timing, but something I'll check when I have time.

[Rabbit TD]

You left out the big one, GLOW PLUGS.  I'm getting mine ready too and found 3 dead ones Saturday

[burn_your_money]

You white smoke issue sounds like timing, glowplugs, or low compression to me. You've already stated that timing is ok so I'd look at the glowplugs next.

[Rabbit TD]

That's a real nice looking intercooler job you did there.  You say you got it off Ebay, was it a kit or did you do the tubing yourself?  I'm gonna try one for my Rabbit this Winter I guess.  It always gets nice presents for Christmas too

[spencebm]

Looks great, good luck adding oil!  haha.  what turbo are you running and be careful with those worm gear clamps, they will be a curse holding almost 30 pounds of boost!  Did you move the battery back?  Is this a mk2 or mk3?  Good work, looks great.

[spencebm]

oh i love the fan also, where did you get that from?   Any boost loss from intercooler?

[zozep]

Looks great, good luck adding oil!  haha.  what turbo are you running and be careful with those worm gear clamps, they will be a curse holding almost 30 pounds of boost!  Did you move the battery back?  Is this a mk2 or mk3?  Good work, looks great.

Thanks! My wife hates it.

Indeed...Funnels are now my friend!

Yes, had to move the battery back, a tray was welded in, just enough space for it, I'm thinking of another of the same battery above the alternator, theres room there too. Has anyone had good experiences with 2 batteries? I'm still wondering if it's necessary.

Tell me about it with the gear clamps! the 200$ kit from fleabay didn't come with 1.5 to 2.5' couplers...so at first had to use Home Depot plumbing adapters...  that didn't work out very welll, they would just pop off at 25 psi or so.
You can tell from the first engine picture, the coupler is blue...the second picture it's red, with the new silicone coupler I got last week. Holds 27-28 psi just fine now.  The bottom of the intake box had to be cut as well, not sure if anyone can tell... the piping just wouldn't fit. So I also have to figure out an airfilter setup, what do people suggest?

And how about incabin noise levels? Has anyone had any luck reducing the drone at highway speeds? I was told that magna flow has a nice highflow resonator that works well... 2.5 inches all the way back is pretty loud let me tell you.

Tyler, Giles said that timing didn't ever really need to be advanced for this pump the way its set, what do you suggest for timing?