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#150
by
Gizmoman
on 26 Apr, 2014 14:25
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As I was pulling in the driveway last night from work, I heard this terrible metal-to-metal sound.
Here's what it was
Amazing how quiet the turbo makes the exhaust - the muffler hardly does anything.
Here's my fix
I also added a rubber support bracket about mid-way in the system to dampen some of the vibrating mass. Hopefully this will do it - or it will simply crack somewhere else. If that happens, I'll need to rethink the entire system - possibly using a flex section.
Driving to work every day to ring out stuff before my upcoming road trip has been a wise move. I found out that the yellow hose (I believe it's silicone) I bought from McMaster Carr to pipe the injector overflow, is too soft when it gets warm. I blew one off and really made a mess of the bay - no telling how long I drove it like that.
I replaced it with some pinkish fuel hose I got at Home Depot (in the lawnmower maintenance section) which seems to be holding up nicely. I had to warm up the ends with a heat gun to put it on and it's much stiffer than the yellow stuff.
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#151
by
burn_your_money
on 26 Apr, 2014 16:43
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I found out that the yellow hose (I believe it's silicone) I bought from McMaster Carr to pipe the injector overflow, is too soft when it gets warm. I blew one off and really made a mess of the bay - no telling how long I drove it like that.
Sounds to me like you have a restriction on your fuel return side. There shouldn't be any pressure on that part of the system.
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#152
by
Gizmoman
on 26 Apr, 2014 17:17
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I found out that the yellow hose (I believe it's silicone) I bought from McMaster Carr to pipe the injector overflow, is too soft when it gets warm. I blew one off and really made a mess of the bay - no telling how long I drove it like that.
Sounds to me like you have a restriction on your fuel return side. There shouldn't be any pressure on that part of the system.
I'll have to check that out. The previous hose was definitely the wrong type though and it got pretty mushy when warm. The way I wrote it "blew-off", may have been an exaggeration - should have said, slipped off.
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#153
by
tdihuntdawg
on 26 Apr, 2014 18:00
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Do you run the 82 or the 83 carrior bars . The 82 have the double shear mot or mounts and rubber bushings at both ends and move around a lot more than the 83 bars which are single s hear andsolid atboth ends.I found out the hard way I needed a flex pipe. And mount supports only off alluminum motor mounts and not the bars or body as they move with engine. Great job GLEANERDAWG
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#154
by
Gizmoman
on 26 Apr, 2014 19:32
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Do you run the 82 or the 83 carrior bars . The 82 have the double shear mot or mounts and rubber bushings at both ends and move around a lot more than the 83 bars which are single s hear andsolid atboth ends.I found out the hard way I needed a flex pipe. And mount supports only off alluminum motor mounts and not the bars or body as they move with engine. Great job GLEANERDAWG
Not sure. I'll bet they are the stock bars though and the van is an 82,
I doesn't vibrate that much, I just think the pipe needed a bit of help. Besides, the 180 bend is nearly paper thin
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#155
by
TimpanogosSlim
on 26 Apr, 2014 20:36
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Driving to work every day to ring out stuff before my upcoming road trip has been a wise move. I found out that the yellow hose (I believe it's silicone) I bought from McMaster Carr to pipe the injector overflow, is too soft when it gets warm. I blew one off and really made a mess of the bay - no telling how long I drove it like that.
I replaced it with some pinkish fuel hose I got at Home Depot (in the lawnmower maintenance section) which seems to be holding up nicely. I had to warm up the ends with a heat gun to put it on and it's much stiffer than the yellow stuff.
The yellow stuff i bought from mcmaster is Tygon Fuel & Lubricant, which is "vinyl" but obviously a polymer specified for fuel and lubricants.
And yes, I kicked myself when i saw the pink "micro fuel hose" at the hardware store for a fraction of tygon. But i have no intention of using the old black hoses or the water-spec vinyl the PO installed. So i have 10 foot lengths of 2 sizes of tygon F&L.
fwiw I am a belt & suspenders guy, so don't be surprised when you see little spring clamps installed on my fuel return hoses that shouldn't need to be there at all.
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#156
by
Gizmoman
on 27 Apr, 2014 06:52
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Driving to work every day to ring out stuff before my upcoming road trip has been a wise move. I found out that the yellow hose (I believe it's silicone) I bought from McMaster Carr to pipe the injector overflow, is too soft when it gets warm. I blew one off and really made a mess of the bay - no telling how long I drove it like that.
I replaced it with some pinkish fuel hose I got at Home Depot (in the lawnmower maintenance section) which seems to be holding up nicely. I had to warm up the ends with a heat gun to put it on and it's much stiffer than the yellow stuff.
The yellow stuff i bought from mcmaster is Tygon Fuel & Lubricant, which is "vinyl" but obviously a polymer specified for fuel and lubricants.
And yes, I kicked myself when i saw the pink "micro fuel hose" at the hardware store for a fraction of tygon. But i have no intention of using the old black hoses or the water-spec vinyl the PO installed. So i have 10 foot lengths of 2 sizes of tygon F&L.
fwiw I am a belt & suspenders guy, so don't be surprised when you see little spring clamps installed on my fuel return hoses that shouldn't need to be there at all.
Belt and suspenders guy - I like that. I bought a "kit" of spring clamps at the FLAPS cause I saw the kit included some small ones for the same reason. They turned out to be junk so I didn't install 'em. I also bought various types of tubing from McMaster to try. I don't recall exactly but the vinyl (I believe it was Tygon) had a liner inside that kept pushing up inside the outer cover when I tried to install it - ugg.
Reliability is my #1 goal and it seems to be a moving target. Honestly, I got pretty deep (maybe too deep) into the R&D side of things with this vehicle and I am looking forward to traveling down the highway without a care in the world. I wonder sometimes if that day will ever come. After I fixed the exhaust yesterday, I started it and noticed my alternator belt was very loose. Hmmm, grabbed a 13mm and a pry-bar and attempted to lift and tighten it -- it WAS tight. Turns out the lower bracket bolt was gone.
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#157
by
Gizmoman
on 27 Apr, 2014 08:33
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#158
by
tdihuntdawg
on 27 Apr, 2014 09:20
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From your photo it looks like you have a full flow oil adapter that goes to filter and then possibly a cooler,then back to engine . I would install a filter in stock location to see if oil pressure improves. It possible you have a restriction GLEANERDAWG
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#159
by
Gizmoman
on 27 Apr, 2014 09:48
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From your photo it looks like you have a full flow oil adapter that goes to filter and then possibly a cooler,then back to engine . I would install a filter in stock location to see if oil pressure improves. It possible you have a restriction GLEANERDAWG
Thanks for the suggestion. The circuit has a thermo-valve that only allows HOT oil to head off to the cooler. I have 80 PSI when I start it in the morning. After it's fully warmed up it idles between 8-12 PSI which is lower than I'd like it but fine from what I've read. Less than 5 would have me worried. At 3200 RPM (cruising at 70 MPH), it runs around 35-40 psi (gauge is digital)
I have a few things that may be causing the low idle pressure like a "custom" ball bearing IM shaft. The outer races of the dual ball bearings blocked the original oil port (to the stock sleeve bearing) so I cross-drilled it to flow oil into the front side of the bearings behind the seal/cover -- should have used a much smaller diameter drill bit.
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#160
by
atg
on 10 May, 2015 06:58
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Here's a shot of where one end of the brace can attach
Did you cut that flange by hand with a torch? Pretty good result I would say.
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#161
by
Gizmoman
on 11 May, 2015 16:56
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Thanks for the kudos - simply many years of doing it (back in my sawmill days).
A few tricks; no more oxygen or gas pressure than needed, preheat a tad, a super clean tip (you should see a long perfect line of oxygen when you pull the trigger), and use a straight-edge guide whenever you can.
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#162
by
spltshft
on 22 May, 2015 11:27
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Just finished reading this thread. Lots of great information in here. I picked up an aaz out of a 97 Jetta that I am looking to put in my daily MK2 golf, and this has given me something to consider. How do find the drivability?
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#163
by
Gizmoman
on 23 May, 2015 05:23
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The vehicle it's in weighs about 4800 lbs and is as far from aerodynamic as it could be.
All I can say is it is much better than the NA 1.6 that was in it before
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Currently I'm not driving it much - saving for a new 5 speed transmission.
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#164
by
VTPSD
on 18 Feb, 2016 06:17
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Hi, I have read through your thread a few times, specifically in regards to the he211 turbo. I have the same turbo on an AHU TDI in an audi 90 quattro. I have a similar oil drain issue, where the drain is below the oil level. I have good fall on the line, but holset claims the oil should not drain below the sump level.
Has your drain as last pictured continued to work without oil getting forced past turbo bearings?
I was pleased to read how much you like this turbo. I cannot wait to try it out on my car.
Thanks,
-Dana