intercooler

[3beejay3]

I was recently over at QuickTD's house and he performed some of his magic on my pump and turbo(97 Jetta TD AAZ). Nothing exotic, just adjustments to the factory settings, modified aneroid pin and upping the boost from 9# to about 13#.  Noticeable difference, almost like a different car.
I wish I'd had this done a couple of years ago.

I'm starting to think about putting an intercooler on the car. The obvious choice would be to get all the hardware from a wrecked Mark 3 TDI. Based on a few calls to some area wreckers these appear to be scarce.

Would the IC(and accompanying hardware etc.) from a mid to late 90's TDI Passat work without major surgery/fabrication?
Was the TDI avail. in the Mk3 Golf?

I can source a new IC for this application for approx. $200.00cdn however I will still need to source/fab everything else.

Any thoughts/ideas?

PS. QuickTD's Jetta really is pretty quick(he's given me a ride in it.) For anyone here that hasn't seen it , he has done a very good job with everything he has done to his car.  Everything was done with a lot of thought and effort. It's worth taking a look at.

BJ

[BlackTieTD]

Bruce comes out to some GTGs so a lot of us have peeked under his hood... his setup is the cleanest custom work of any of the cars at the GTGs in Dorchester. All well thought-out. You should see if he'll make you an IC setup like his!  :twisted:

[jwspin]

it is pretty easy to get an intercooler from a mitsubishi eclipse or ford probe to fit on an mk3. you just need to make some brackets, which is very easy with some self tapping screws and a drill.

-jared

[3beejay3]

re intercooler from Ford Probe or Mitsubishi.

Where would you mount this style of intercooler? Will they easily fit in the stock location underneath the left headlight?

Bruce- Do you have an estimate of how much beer it would cost to do something similar to yours except  mount everything on the left side as we talked about?  :lol:  :wink:

BJ

[QuickTD]

Bruce- Do you have an estimate of how much beer it would cost to do something similar to yours except mount everything on the left side as we talked about?  

 You have to remember that my IC setup was built by a dude with bunch of time on his hands... I don't believe they make enough beer to cover it.  I've seen under the hood of a TDI passat and I think the passat hardware would still make a good starting point. I'll have to check and see exactly what parts are actually interchangable. Doing a full custom set of pipes down into the fender like the TDI would be a serious pain, thats the reason I built mine the way I did...

[QuickTD]

I've seen under the hood of a TDI passat and I think the passat hardware would still make a good starting point.

Upon further investigation, maybe not. The passat IC system shares exactly nothing with the Jetta, well maybe the hose clamps... I guess the search continues...

[3beejay3]

Bruce- what source do you use to search parts interchangeability?

You have to remember that my IC setup was built by a dude with bunch of time on his hands... I don't believe they make enough beer to cover it.

I assumed it would take roughly several tractor trailer loads or maybe the output of a brewery in a years time etc. :lol:

Found a MK3 TDI Jetta in a wrecking yard nearby but one of their employees scooped the engine and intercooler for a project he was working on :cry:

[QuickTD]

I use Etka, the VW illustrated parts catalog. Always at my local dealer of course, since us civilians aren't allowed to have it... :wink:

[A2TD]

Have you ever tracked your car Quick TD ??

[QuickTD]

Have you ever tracked your car Quick TD

No, I haven't. It's my daily driver so it's relatively tame, I need to keep it running... Giles and I gteched it last fall with a guesstimated weight of 3000lbs, we came up with 88hp. It was in a pretty sedate state of tune at that time, zero smoke and 12psi. I've done some more pump tweaking since and added more boost, since I now have a spare motor  . It smokes lightly at the current 14-15psi and feels considerably faster, butt dyno says ~100-110.

 My car is nothing, for a real ride you guys have got to try Andy's sequential turbo 1.9 A2 jetta, It's insane  :twisted: . It is bar-none the fastest diesel car I've ever ridden in, TD,TDI or otherwise. I would be very interested in knowing what it's putting down...

[935racer]

Any pics of taht setup? How much boost? Any internal mods? Dynos #'s? Sounds cool

[andy2]

Sorry I don't have a digiltal camera,However Dr Diesel has a pic or two of the turbo setup if he could possibly post them up :wink:.The engine is fully balanced,has lightened AAZ con rods,12.9 grade capscrews holding everything together,smaller I shaft pully to up oil pressure with shorter 1.6 timing belt,Ported head,3 notch head gasket,GTD nozzles,Giles pump(soon to be 12mm),crappy FMIC,K24/K14 ported Hybrid with Holest Hx30 ontop,2.5"stainless mandrel straightpipe.2L 16v pressure plate W/refaced diesel disc.I have a 30 psi boost gague and need a bigger one :twisted:.after I get my new pump dialed in I'll a least get a G-tech reading.

[malone]

Dr Diesel has a pic or two of the turbo setup if he could possibly post them up :wink:

Finally! Let's see em

A couple questions:

1) Are the lightened AAZ con rods custom? If yes, where did you get them?

2) How well did the lightened rods improve revving?

You can PM me the answers only if you don't feel like posting them here I'd appreciate it.

[andy2]

They are lightened OEM ones,Just cut the chunk off the caps,Then resized and balanced them.I could have just went with early TDI ones as they are the same only already missing the chunks of the caps :roll:

I'm using an 8lb flywheel as well.Right now I don't have any useable power beyond 4500 rpm and I'm still more happy with it,The 1.9 has gobs more torque down low compared to the 1.6 especially with everything lightened it gets to 4500 in a hurry.

[malone]

Gotcha, I figured that they may be OEM rods but I was uncertain if their strength would be compromised by lightening them.. the caps make sense though.

Sounds like you have a torque monster!! I look forward to your G-Tech results. I should have mine up soon.