My '96 Golf TD - AAZ

[JavaMan]

My car is a '96 Golf GL TD - AAZ.
Have been reading here for a while, figuring out what I want to do with her.
 - Bought some 17" wheels, and KYB shocks/struts.
 - Replaced the rear trailing arm bushing. (now that was a PITA)
 - MOMO steering column adapter.
 - Made a steering column to steering wheel adapter plate
 - MOMO steering wheel (F1 Ferrari United Colors of Benetton).
 - Quick release for steering wheel.
 - A-pillar triple pod.
 - Pyrometer gauge.
 - Oil pressure gauge.
 - Boost gauge.

Been playing with the "Make your 1.9TD a faster car " article,
slowly making the 75hp engine get some power.
So far I am getting about 1.5 Bar (21 psi) boost and it is hardly pushing any smoke out.
Am thinking of making it into a Harlequin Golf.

Cheers,
Lenn

[8v-of-fury]

NICE CAR. Careful with that 21psi.. You most likely have the k03 or the worse off GT15.. The K03 is not too happy over 17-18 and the GT15 is less than that.

I'd check what you have, you could suffer turbo failure from that PSI. Do you have an inter cooler? Pointless to run so much boost without one, it is ingesting super hot air and taking power away. Get an IC on there next!

[JavaMan]

Thanks, as I don't get out much to drive, so should be safe.
I get to walk to work, about 10 minutes each way.
So I only go out driving on my days off. 
But, I have just won on ebay a FMIC (Length: 22.50", Width: 3.25", and Height: 6.50")
So that, along with a cold air intake I'll be making, will be next.
As for what kind of turbo, how can I tell?
Have been looking at the T3/T4 on eBay that sells for $130.
Is there much difference with internal/external waste-gate as far as function/power?
Am kinda wanting to hear the BOV when I let off the pedal. (yeah, a lot of folks don't like them)
Would it be easier to add a BOV to one with external WG?
enough for now.. heh heh.. will ask more as time goes on. 

[8v-of-fury]

You will never be able to have the "WOOOOOOSH" noise the gas engines have. They have throttle plates that close increasing intake tract pressure and thus it needs to "blow-off" or else it would pop all the boost hoses off. Sorry to break your heart.. haha.

Look up what each turbo looks like, and then look to see what you have. Also you could inspect your turbo and see if it ihas an identifying tag. Pretty sure the GT-15 will have a stamp of GARRET on the compressor, and the K03 will have three k's in a triangle.

This is a KKK-24 so not what you have, but the triangle k's are pictured;

[bbob203]

what transmission do you have java man?

[JavaMan]

Oh man, you're killing me.. turbos and W00000SH are like meat and potatoes they just go together. heh heh
I guess I have the K03, saw the triangle after taking some hoses off of it.

As for what transmission I have, manual if that is the simple answer you want.
If not, will have to find out what my options are and see what it really is.
I do know that it goes 50km/h (30 mph) at about 2100 rpm in 3rd gear.
As my speedo is flakey, and isn't always working, must have a corroded connection somewhere,
so I drive by my rpm hahaha

Cheers,
Lenn

[bbob203]

I guess I wonder if its an 020 or an 02a. 020 cable 02a hydraulic.

[8v-of-fury]

Golf did not get the 1Z/AHU TDI or 02A at all. They started in 1999.5 with the ALH and 02J.

This will be a 020 for sure as it is an AAZ, unless it was swapped.. but I doubts.

[JavaMan]

How much play should there be on the turbo fan?
When I had the hoses off of it to see what kind it was,
I did a quick check on the side to side and end play.
It seemed noticeable, like maybe a millimeter or so.

[RabbitJockey]

How much play should there be on the turbo fan?
When I had the hoses off of it to see what kind it was,
I did a quick check on the side to side and end play.
It seemed noticeable, like maybe a millimeter or so.

there is always some end play on a turbo even a rebuilt one, 1 mm is too much, but im sure u were just guesstimating

[JavaMan]

Kewl, thanks for the info about my transmission and also about the turbo end-play.
(bought a dial indicator kit to be able to test end-play and other fine uses.. should arrive soon)

Well, my cone shaped air intake arrived, just removed the old air box and installed it.

Also a few days ago my intercooler arrived. 22.5" x 3.25" x 6.5" .. just a wee bit bigger than I had imagined.
Oh wells, now I just need to fit it in there somewhere.

And just this morning my 2" piping for it also arrived. So I can start the installation soon. 

[bbob203]

the stock airboxes are great for these cars. Im actually going to redo my intercooler piping so i can run one. The aftermarket "highflow filters" let in more air but also larger particulate to cause more wear on valves and turbo. Not to mention paper filters are cheap and flow plenty especially on a car with a turbo. IMO and based on lots of research.


I should also add I say so not to sound like i know everything(i know very little compared to some) but to offer advice and help improve your experience!