VW 1.6 NA to Turbo swap! Questions and Progress.

[Tmarkle]

Well more great news! Injection pump is shot... when turning the motor over by hand the belt tries to walk off the pulley, and with the belt off the pump had a pretty good amount of play. This car is becoming addicted to my paychecks! Lol


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[air-cooled or diesel]

dude, looking at prev pages & pics, i couldnt be sure, looks like you made one under estimation of your project. recent problems aside, which i hope you can get straightened out. what id like to point out and the question. is your exhaust one solid (&welded) piece to the turbo? that is a problem.
the factory old style (basic-hook up) the toilet bowl exh hook up, set up was an easy basic way to kind of 'separate' the exhaust. as one single piece the exhaust is now a solid extension, or lever of the whole engine. the old toilet bowl allowed a separation of the beginning of the exhaust and the rest -length of the exhaust. if its solid the whole exhaust is now a (solid) lever, where as you torque the engine the whole lever is dependent on the motor mounts, and you can ruin the exhaust and have all that torque going down to the muffler and tail pipe. on the 'newer' mk3's like ive kept up on and most newer cars as i take it, theres a separation (also) they will have a flex pipe, so the rest of the length of the exhaust (under the whole car) can just 'hang' there. the front part, the motor can now rotate, torque on the motor mounts.

[Tmarkle]

dude, looking at prev pages & pics, i couldnt be sure, looks like you made one under estimation of your project. recent problems aside, which i hope you can get straightened out. what id like to point out and the question. is your exhaust one solid (&welded) piece to the turbo? that is a problem.
the factory old style (basic-hook up) the toilet bowl exh hook up, set up was an easy basic way to kind of 'separate' the exhaust. as one single piece the exhaust is now a solid extension, or lever of the whole engine. the old toilet bowl allowed a separation of the beginning of the exhaust and the rest -length of the exhaust. if its solid the whole exhaust is now a (solid) lever, where as you torque the engine the whole lever is dependent on the motor mounts, and you can ruin the exhaust and have all that torque going down to the muffler and tail pipe. on the 'newer' mk3's like ive kept up on and most newer cars as i take it, theres a separation (also) they will have a flex pipe, so the rest of the length of the exhaust (under the whole car) can just 'hang' there. the front part, the motor can now rotate, torque on the motor mounts.

Going to run a flex joint after the down pipe so that nothing mentioned will cause a problem.


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[air-cooled or diesel]

hate to be a multiple critic; only trying to help. butt i thought id mention..

your intake being solid is quite the same. you need breaks, normally 2 are needed, the closest 2 to the motor. rubber hoses at the intake, (&clamps),any more are additional, like 2 on either side of the intercooler.  rubber can flex.

[Tmarkle]

hate to be a multiple critic; only trying to help. butt i thought id mention..

your intake being solid is quite the same. you need breaks, normally 2 are needed, the closest 2 to the motor. rubber hoses at the intake, (&clamps),any more are additional, like 2 on either side of the intercooler.  rubber can flex.

Using a metal reinforced flexible radiator hose between the turbo and the blue charge pipe. Plenty of flex there lol


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[air-cooled or diesel]

thats one side of the intake, iirc, you installed an intercooler, so you have one line coming out of turbo, you say that one you have a rubber line on it, you now have a solid line to intercooler, in this case and on the other side on intercooler another flexible connection is real smart, then you will/should have another solid line back to intake(manifold) this needs a flex connection here. the next smart reason for flex rubber hose connection in all these spots is accessibility, you can now service most of that system just as easily as well.

[Tmarkle]

hate to be a multiple critic; only trying to help. butt i thought id mention..

your intake being solid is quite the same. you need breaks, normally 2 are needed, the closest 2 to the motor. rubber hoses at the intake, (&clamps),any more are additional, like 2 on either side of the intercooler.  rubber can flex.

Using a metal reinforced flexible radiator hose between the turbo and the blue charge pipe. Plenty of flex there lol


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No intercooler, I know it looks like it drops down to a fmic but the easiest way to attach the charge pipe with how the K03 sits compared to the 1.8 intake manifold was to loop down and back. It will evening get an intercooler which is part of the reason I fabbed the charge pipe that way.


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[air-cooled or diesel]

so your good on the 'front side', its just the 'back side' there you need some help as i suggested, and gl with the other fixes, it usually is an investment. if you get it working right you may have a long time to enjoy it and tweek it.

[RabbitJockey]

on the valve seal conversation, i just did mine, i just smothered mine in assembly lube and gently pushed them in the seals, so hopefully there was no damage, i didn't see any nicked pieces in the grooves or anywhere else.

[Tmarkle]

This is the TDC mark correct? Crank turned just a bit by accident with the belt off.


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[ORCoaster]

That is what mine looks like except I painted it Red in the notch so I could see it better in low light conditions.

[vanbcguy]

Yes

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[Tmarkle]

So I'm probably in denial that the pump needs rebuilt or replaced, but is there anything else that could cause the belt to walk onto the lip of the IM shaft pulley? The IP shaft has some play but I would think that I would have had this problem the first time I had the belt off. The belt did loosen up after a however long between these repairs but I figured it was my substandard homemade tensioner tool or simply the tensioner being worn. Now that I think of it I may have forgotten the bolt that goes from the mini bracket to the back of the IP, would that cause this?


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[libbydiesel]

You can adjust the belt tracking by adjusting the injection pump bracket.  I've described how about 8 gazillion times in the archives.  I'm too tired to type it again.

[Tmarkle]

You can adjust the belt tracking by adjusting the injection pump bracket.  I've described how about 8 gazillion times in the archives.  I'm too tired to type it again.

Thanks, I'll take a look!


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