Finding the limit of my turbo and ended up cleaning whole engine and bay! - User's ride Wall - VWDiesel.net The IDI, TDI, and mTDI source.

• Finding the limit of my turbo and ended up cleaning whole engine and bay! by james277553 on 22 Jun, 2012 16:13
• So after 187,000 miles my turbo decided that it didn't like 20psi pushing though it and started to whistle like a pig. This wasn't what I wanted after spending all last summer doing up rest of the car.
  I managed to locate a good second hand turbo and started to try and remove old turbo with engine in the car. No chance that was happening so out the engine came. I've never done this before so was a big learning curve. I figured i'd rebuilt rest of car so how hard can engine be lol. He some picture of what I got up to. And yes once you start its hard to know when to stop. Sorry for mass of pictures.
  
  
  
  
  
  
  
  20 years of driving on wet and muddy roads had taken it toll.
  
  
  
  I decided to fit a splash guard in the sump and also knock a dent out of the sump from a large stone hitting it at 60mph!
  
  
  
  
  
  
  
  
  
  
  
  Lots of De-greaser later and alot of scrubbing:
  
  
  
  
  
  I found out why my gear selection was so bad. I really recommend replacing these if you get gearbox selection problems only cost £10
  
  
  
  
  If your not bored yet more pics to come:
  
  
  
   
• #1 by james277553 on 22 Jun, 2012 17:05
• I couldn't believe how much wax was still in the engine bay. It took me hours to clean it all off. I kept finding bits. Then I attacked it with the pressure washer and more de-greaser.
  
  
  
  
  
  
  
  
  
  
  
  
  While the paint was drying I started to rebuild engine, there's not many pictures of this. I got into bolting bits on too much and forgot to take pics.
  Ended up with new oil cooler as the old one has corroded badly wasn't happy to find but glad I did while it was apart.
  
  
  
  I also changed the gearbox oil man it was black, I kept flsuhing it till all the black burnt oil was gone.
  
  
  
  
  
  
  Weighted shifter is a must have
  
  The wiring was fun to put back. I'm glad I took pictures.
  My wife had our baby boy in between times and so didn't touch the car for about a month.
  
  I couldn't resist and ended up with a new power steering bottle and expansion tank. 
  
  
  
  
  The first run went really well and all seemed to be fine with only a problem with a split water flange.
  It was then time for my intercooler to be put back on.
  
  
  Once engine was running and everything sorted I made up and new 2.5" exhaust as old stock system was just not good.
  I'm not waiting for a custom rear silencer to be made so driving round with a straight though exhaust it sounds good but too loud for my liking. The power is very good now and running about 19-20 psi. I did a few 0-60 mph tests the other day and I can get just under 10seconds. I think I could do a 9s on flat ground. I live in Devon never seem to have a flat run.
  
  I realised I haven't taken any pictures of the completed job I will try to take some soon to finish this post off.
  Hope you like     
  
  
  
     
   
  
  
   
• #2 by james277553 on 22 Jun, 2012 17:11
• Sorry for the double pictures not used to doing this and getting tired it 1am in the UK need sleep. I missed the picture of my new exhaust.
  
  
  
   Its a bit DIY but got to be better than stock.
   
• #3 by randylovepump on 23 Jun, 2012 12:09
• top work mate looking good
• #4 by GTFORZA on 23 Mar, 2013 13:09
• That's a beautiful engine bay!!!!!!!
• #5 by 745 turbogreasel on 23 Mar, 2013 14:07
• Congrats on the most elaborate turbo swap ever
  Quite a transformation.
• #6 by shorttimer on 23 Mar, 2013 18:52
• Nice job! I need your enthusiasm. I'll bet that new pipe really made a big difference. The stock ones are so restrictive.
• #7 by carrizog60 on 24 Mar, 2013 02:43
• congrats for the baby and the love on the car!
• #8 by snakemaster on 26 Mar, 2013 15:24
• Looking good , that lookes to be a nice intercooler