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Engine Specific Info and Questions => IDI Engine => Topic started by: 53 willys on September 08, 2008, 02:28:38 pm
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I used to have a 91GLI in highschool and ended up selling it cause I did not like the VW gas engine but the car was still to this day my favorite car to drive...a few months ago I found Zukgod1's Jetta build and I fell in love with it....it inspired my to find a GLI like I used to have and put a 1.6TD in it.
So here is my build up and progress...I need to thank Zukgod1 for all the help so far..I am always bugging him with new questions and concerns..I also need to thank Myke welch for all his help with parts and rebuild questions..also this forum and it's members for a great site with TONS of diesel info!!
thanks guys!
here is the car I picked up..clean one owner..the guy who I bought it from had it in cali for it's whole life so it has ZERO rust it's a German built model..he picked it up on the import program..
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0403.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0404.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0406.jpg)
dirty old 1.6TD ready for rebuild..
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/16td1.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/16td2.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/16td3.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/16TD4.jpg)
K24/26 hybrid...I got board so I cleaned, rebuilt and polished my K24/26
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/hybridturbo.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/hybridturbo2.jpg)
I pick the engine up tomorrow then the ARP stuff goes in(head studs,rod studs and oil pump bolts) and the fun really begins!!
I lighted the flywheel and also lighted the intermediate shaft.
I also have a clutchnet.com 210mm race clutch for this setup.
more pics and info to come!!!
:twisted:
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Let me know what your schedule is once you get your parts. I can stop on the way home and help for a while a few days a week..
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I love diesels and all, but why in the hell would you molest such a beautiful car?
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Ha, you should have seen the remarks like that when he posted this over on the vortex.
This will be a very nice TD when he is done.
They didn't wrap a car this nice around a diesel. No recaros for us, no BBS rims,... rear wing? MFA? no,... anyone have a diesel with electric windows? Might be a couple of those but we got ripped off and this is our revenge,... I am living vicariously through 53 willys :lol:
Whaat? Want him to have a beater looking Jetta GLI TD? He deserves the best, we deserve the best,..
we got ripped off man :evil: :x :cry:
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There is no molesting it could go right back to the gasser quite simply. I would love to take a beautiful car like this and convert it. Keep it up.
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thanks guys!!! yeah the purist on Vortex were really pissed at me!! :lol:
I love VW's but not their gas engines...I am a full blown diesel dirt head, I don't see this as ruining or molesting a beautiful car...I see it as making a all ready beautiful car even better :wink:
you guys know diesel engines are better then gas...so this is a improvement to a all ready nice car...why in the world would I ever convert it back to gas!!! :lol: :twisted:
I think even the nay sayers will like this build when I'm done.
Cheers
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Sexy!
That's all Ihave to say.. :twisted:
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Diesel conversion a downgrade?
Are we trying to keep our hands clean or something...
Who on earth said that???
Someone who doesn't know what torque is obviously :twisted: :twisted:
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I love diesels and all, but why in the hell would you molest such a beautiful car?
:lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol:
You say "molest" most of us say "improve".
Going to be a SHAWEET CAR!!!!!!
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Which transmission are you going to use?
Are you going to hook up the instrument cluster? I used the oxygen sensor light for my glow plug light, but it was backwards, so I needes a relay to reverse the polarity.
I was gonna use the 2Y trans...but I found a ASF(taller 5th gear) at my local wrecking yard for $65..so I pulled that to use...but I also have to swap axle flanges since the 2Y has 100mm flanges and the ASF has 90mm.
I am not sure on the cluster yet..my cluster has white faces and I REALLY want to use it..I think I am gonna pick up a parts cluster and use the flexible board and the tach from it....BUT i also really want to use the cluster computer that the GLI has cause it has a oil temp sensor and a few other cool sensors.
as for glow plug light..I found a glow plug LED from a diesel and I would like to put it in my cluster...but i'm not sure if it will work yet?
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There are a few tach converters that you can use to keep the MFA cluster. This one isn't a converter per say but it's pretty cool and gives an accurate reading: http://www.4crawler.com/Diesel/CheapTricks/Tachometer/index.shtml
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anyone have a diesel with electric windows?
Me!!
53 willys, GO FOR IT!!, if VW hadn't viewed american diesel buyers as total skin flints we would had more diesels without manual windows! Convert it back to gas??? Why??
The difference between the Carat and a Plain Jane GL TD I swapped is night and day, a GLI even more so.
Molest?? No Way!!! Improvement I say!!
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I can understand the 16v crowd flipping out about it. There's a saying about 16v fans and owners, something like "they think they've got god's balls under the hood" So to these people, you are essentially cutting off . ..
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a little 16v is God's balls? LMAO. I'd call that short-man envy. A weiand 6-71 strapped to a Banks 355 with a dual pumper and a Muncie rock crusher...now you're getting somewhere.
I think your project is great. Good for you. As long as you're happy with it, who cares?
Andy
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16 valves = just more valves to bend :lol: GO DIESEL!
your car is MINT!!
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haha thanks guys...much better response then I got on vortex...lol
got some more goodies today :twisted:
210mm race clutch with small 24 splines for the ASF trans.
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0428.jpg)
clutch, ARP head studs and dual A-pillar pod
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0429.jpg)
G40 polo valve cover
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0433.jpg)
lightened IM shaft
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0434.jpg)
cleaned up ASF trans next to the GLI 2Y
I still need to swap the flanges....just waiting for my seals from Myke.
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0432.jpg)
DIY port and polished head
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0431.jpg)
the machine shop peened the cracks between the valves
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0430.jpg)
also got my Benz tiped injectors!
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/injectorMB.jpg)
almost ready to put this beast together!!
:twisted:
i was gonna run a metal head gasket...but I am just to scared of the mods to make it work....if I blow the stock fiber then maybe I will try the MLS gasket.
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I'm jealous of the clutch for sure!!!
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for anybody who cares.....here is some small tech..
the transfer pump in the fuel tank of the gas VW's output is 6-7psi...I am gonna run it as a lift pump for my diesel conversion.
this is a perfect PSI for a lift pump 8)
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mmmm... Nice parts. :D
BTW: I think that might be a G40 valve cover, the G60 has the oil fill and PCV holes reverse of yours, at least mine does.
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for anybody who cares.....here is some small tech..
the transfer pump in the fuel tank of the gas VW's output is 6-7psi...I am gonna run it as a lift pump for my diesel conversion.
this is a perfect PSI for a lift pump 8)
i thought that the pressure for the mechanical injection was 35 psi or so?
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mmmm... Nice parts. :D
BTW: I think that might be a G40 valve cover, the G60 has the oil fill and PCV holes reverse of yours, at least mine does.
your probably right?? the guy I bought it from said it was a G60...but all the g60 ones I have seen are slightly different then mine. there was no pic in the ad so I never saw it till it showed up :oops:
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for anybody who cares.....here is some small tech..
the transfer pump in the fuel tank of the gas VW's output is 6-7psi...I am gonna run it as a lift pump for my diesel conversion.
this is a perfect PSI for a lift pump 8)
i thought that the pressure for the mechanical injection was 35 psi or so?
I put the sending unit in a bucket of diesel last night and put a gauge on the output line of the pump and my gauge read 6-7psi....the high pressure pump that the transfer pump feeds is like 78psi
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mmmm... Nice parts. :D
BTW: I think that might be a G40 valve cover, the G60 has the oil fill and PCV holes reverse of yours, at least mine does.
your right I just did some googling and it's a "polo G40 valve cover"
I guess that will work???
I even found one installed on a diesel!....http://forum.myspace.com/index.cfm?fuseaction=messageboard.viewThread&entryID=54226001&groupID=100000193&adTopicID=2&Mytoken=7854EEBD-5DEE-4859-870F9CB092A7795A2139473
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haha mint man, cant wait to see this done, come back to the vortex when its done...im sure they will be like "ohh thats sooo coool, howd yuou do itt" bunch of nut swingers lol
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nop, not a G40 valve cover for sure, G40 has a pipe going through it.
also, the G40 engine isn't based on the 827 design, so the valve cover shouldn't be compatible.
it's very nice anyway, me wants :D
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for anybody who cares.....here is some small tech..
the transfer pump in the fuel tank of the gas VW's output is 6-7psi...I am gonna run it as a lift pump for my diesel conversion.
this is a perfect PSI for a lift pump 8)
i thought that the pressure for the mechanical injection was 35 psi or so?
CIS is approximately 70-75psi injection pressure, but has two pumps to attain that. The in-tank lift pump is very low pressure, and it feeds the primary, external high pressure pump.
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so is that a G60 or G40 cover??? I'm confused??
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I thought it was a G40 but I guess not, maybe two styles of G60??
It'll work, just have to shorten / replace the PCV hose.
Not sure if you bought these yet but....
Make sure you use the rubber valve cover gasket with it and have the plastic oil splash shield under it. If you do that, you'll have to learn to live without the usual VW diesel valve cover leaks. :D
Rubber valve cover upgrade kit (comes with studs) is 026 198 025 C German Auto Parts (http://www.germanautoparts.com/Volkswagen/Jetta/Engine/102/3).
Splash shield Part # is 026 103 547 and is available for $5-$7 (http://www.busdepot.com/details.jsp?partnumber=026103547)
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I thought it was a G40 but I guess not, maybe two styles of G60??
It'll work, just have to shorten / replace the PCV hose.
Not sure if you bought these yet but....
Make sure you use the rubber valve cover gasket with it and have the plastic oil splash shield under it. If you do that, you'll have to learn to live without the usual VW diesel valve cover leaks. :D
Rubber valve cover upgrade kit (comes with studs) is 026 198 025 C German Auto Parts (http://www.germanautoparts.com/Volkswagen/Jetta/Engine/102/3).
Splash shield Part # is 026 103 547 and is available for $5-$7 (http://www.busdepot.com/details.jsp?partnumber=026103547)
thanks for the tips...yeah I already picked up the shield and the rubber gasket and studs....lucky for me Zukgod1 is in the next city over and he has been helping me with all the parts and things I need too.
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so my K24/26 hybrid is a water cooler version....
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/hybridturbo2.jpg)
I know some dont like this set-up but I got the turbo cheap and I will run it till I can afford a ball bearing turbo....anyway I am wondering how the water lines should be plumbed?? does anybody have pics of the water line plumbing on a VW diesel?? anything I should know about plumbing it??
Zukgod1 was telling me you can run it without the coolant lines....But i dont have a problem plumbing the lines and if it helps cool the turbo it should help it last longer so I would like to run them unless there is some other issue I am not aware of???
thanks in advance
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I punched out the gas tank to fit diesel nozzles this week..I used some 1.5" DOM tubing and heated it up with a propane torch...punched out the little metal flapper...I was nervous if it would work but it actually worked better then I expected!
forgot to take the camera over so all I have is phone pics..and I forgot to snap a pic of the tank opening.
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/gastankpunchout.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/gastankpunchout2.jpg)
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Yep, wasn't sure if I was just lucky the little metal flapper came out so easy, glad it came out so easily for you too.
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So, I guess I'll still be the voice of reason (or dissent in this house). Shame what you're doing to that GLI. It's an exhilarting ride. No diesel can touch the RPM whooosh of a 2.0 16v. It's a different type of thrill that starts in the guts, and moves up to the brain. Diesel is all torque, but the 2.0 16V was vws first really sexy engine, and it lived up to the billing: quick throttle response, high revving, and seat of your pants performance.
Despite my misgivings: at least, it looks like you're doing it with class. So, I guess the back-handed compliment is: looks good, despite the molestation. I guess those failure-prone motronic control modules and the hybrid CIS/motronic ECUs are enough to turn off even the most avid VW nut.
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53 willys , your TD is gonna be faster than any 2.0 16v ;)
at least that's my goal
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Yep, wasn't sure if I was just lucky the little metal flapper came out so easy, glad it came out so easily for you too.
hey buddy I need to thank you for the great advice on do this fuel tank mod!!
I probably would have pulled the tank...put a vacuum in and drilled the filler neck out :lol:
thanks for the sweet trick!
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So, I guess I'll still be the voice of reason (or dissent in this house). Shame what you're doing to that GLI. It's an exhilarting ride. No diesel can touch the RPM whooosh of a 2.0 16v. It's a different type of thrill that starts in the guts, and moves up to the brain. Diesel is all torque, but the 2.0 16V was vws first really sexy engine, and it lived up to the billing: quick throttle response, high revving, and seat of your pants performance.
Despite my misgivings: at least, it looks like you're doing it with class. So, I guess the back-handed compliment is: looks good, despite the molestation. I guess those failure-prone motronic control modules and the hybrid CIS/motronic ECUs are enough to turn off even the most avid VW nut.
hahaha I driven enough 16v 2.0 vw's....nothing special.
this is why I cant post it on vortex....Die hard purists!
Diesel power for the win :lol:
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So, I guess I'll still be the voice of reason (or dissent in this house). Shame what you're doing to that GLI. It's an exhilarting ride. No diesel can touch the RPM whooosh of a 2.0 16v. It's a different type of thrill that starts in the guts, and moves up to the brain. Diesel is all torque, but the 2.0 16V was vws first really sexy engine, and it lived up to the billing: quick throttle response, high revving, and seat of your pants performance.
Despite my misgivings: at least, it looks like you're doing it with class. So, I guess the back-handed compliment is: looks good, despite the molestation. I guess those failure-prone motronic control modules and the hybrid CIS/motronic ECUs are enough to turn off even the most avid VW nut.
Why dont you buy the 16v from him? Sounds like you like them maybe you need one? :roll:
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got a pic of the governor mod..
I use a steel roll pin for mine...it fit the shaft real nice and allowed the spring to stay on there for some slight give...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/govmod.jpg)
also got my ARP studs installed
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/studs.jpg)
stock 2 notch gasket...1mm over bore pistons
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/studsandHG.jpg)
I replaced some more seals on the trans...while I was doing that I decided I would change that bushing in the end of the shaft...I had to make a tool to pull it out...I ended up using a tap welded to some nuts..then the nuts attached to the slid hammer...worked great!
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/transbushing.jpg)
the engine is put together for the most part...I should have it installed by middle of next week(my next days off)
if I can get my coolant hoses by then I may even drive it next week 8)
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Lookin' good man... keep those pictures coming... we loves us our build threads !!
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Lookin' good man... keep those pictures coming... we loves us our build threads !!
thanks Vince!!
these are some older pics I had from my phone...I got a lot more done to is this week...I will have some more pics this coming week....I will also have some pics of your glow plug pimping..little different version but the idea is yours 8)
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well I have got the turbo mounted and pretty much got the supply and drain lines figured out....
I had to make a spacer for the turbo so it would not hit the intake manifold...it worked really well and was super easy to make.
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0435.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0438.jpg)
more spacer shots...you can also see my BOV eliminator cap...Zukgod1 gave me the idea....you take a VW strut cap turn it down till it fits in the same spot as the stock BOV and I also weld in a 1/8" NPT steel fitting for my boost gauge...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0445.jpg)
here you can see the oil drain....
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0440.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0441.jpg)
I cut the stock metric threads off the pan and welded a -AN fitting (10) to the old metric pipe fitting....I LOVE -AN fittings so I wanted to change so I dont have worry about finding weird fittings or threads for a drain.
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0442.jpg)
-AN oil supply and and -AN water supply too...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0439.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0444.jpg)
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Clutchnet.com race sprung hub clutch and lightened flywheel
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0436.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0437.jpg)
pretty much got everything ready now!!!
this here is a beautiful thing!!!! 8)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0443.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0448.jpg)
kinda cleaned up engine bay...I still gotta gut the stuff I dont need out og the harness...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0449.jpg)
got my new gauges installed too!!! 8)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0451.jpg)
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I'm stopping by to see this sexyness tonight!!
That turbo spacer looks really good there man..
I wish I would have had one of those so I didn't have to grind the livin piss out of my compressor..
May need one to clear the new intake manifolds though ;)
Not to sure how excited I am about building a new oil drain and down pipe though.
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Has anyone put a small electric radiator fan near the turbo? Ideally it would run only at low speeds / stops as I would think at high speed you have enough airflow back there. Or, maybe run it all the time.
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Ya know with a after run pump you could actually plumb in a heater core mounted in the fender and just run a separate system all together.
Something to consider I guess.
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Well I made some exhaust this week..I spent about $200 total for the 3" mandrel bent turbo back system.
of coarse all the labor is me witch is the only way I can afford my projects :lol:
it not a tig welded PP down pipe....but I am kinda proud of this one.
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe1.jpg)
painted with some 1500* flat.......yeah I know it will probably burn off.. but the same stuff lasted over a year on my cummins....
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe2.jpg)
downpipe
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe9.jpg)
downpipe connection
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe8.jpg)
over the axle arm
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe6.jpg)
4" gloss black turndown..
:twisted:
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe3.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe4.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/downpipe5.jpg)
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engine in!
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/enginepics.jpg)
G40 valve cover back from powdercoat
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/enginepics1.jpg)
glow plug relay base..
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/glowplug.jpg)
glow plug wiring...in place of old ECM...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/glowplug1.jpg)
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Well at least you've been busy taking pictures :lol: :lol: :lol:
Looking good man!
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yeah progress has been slower then I want....all the little things have been sucking up my days...I got most the little things figured out this week so I should be starting it up and driving it next week!! :twisted:
the oil drain and supply and also the coolant supply and drain have been tricky.....
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thats an odd valve cover all of mine have the oil fill on the normal passenger side where yours is opposite! and i have 3 of them!
wher you find that one at?
other wise looks good!
keep the pics. coming!
Duane
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Congrats! That is one of the cleanest engines I've seen. :shock:
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thats an odd valve cover all of mine have the oil fill on the normal passenger side where yours is opposite! and i have 3 of them!
wher you find that one at?
other wise looks good!
keep the pics. coming!
Duane
yeah I dont know whats up with that cover?? I bought it from a guy on Vortex... the ad had no pics...anyway I am glad it has the oil filler on the drivers side cause my intercooler piping would cover the oil fill cap if it did not come on the drivers side.......some one said it was a G40 polo cover??? but I have no clue??? :oops:
thanks for the kind words 8)
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Congrats! That is one of the cleanest engines I've seen. :shock:
thanks...I need to post some before cleaning and after cleaning side by side shots!!!
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I just looked at the pics again. Did you paint the injector bodies?
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I just looked at the pics again. Did you paint the injector bodies?
no they are just new china injectors with merc tips....
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Which clutch disc did you use? And did you get your flywheel from clutchnet? I was thinking of getting the 6 puck or the organic disc.
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before cleaning
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/16td1.jpg)
after cleaning
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0448.jpg)
pretty big difference! what a PITA it has been cleaning all these parts...
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this is a fantastic build!!Good flippin job ,man!After its all done,you will reap the rewards.
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Which clutch disc did you use? And did you get your flywheel from clutchnet? I was thinking of getting the 6 puck or the organic disc.
well I am running the 210mm flywheel from the 16V trans(2Y)...I cut the ring off myself..so its just a lightened stock 210mm flywheel.
I got this clutch disc..it is the smaller 24 spline to fit my ASF trans I converted in....AND it has the 210mm diameter to fit the bigger 16v flywheel.
http://www.clutchnet.com/product.php?productid=18192&cat=0&page=1
then I used this pressure plate...again it's for a 16v since I have the 210mm flywheel....
http://www.clutchnet.com/product.php?productid=20986&cat=0&page=1
I called them to make my order just to make sure I was getting the right stuff...they are easy to deal with so it's no big deal...
8)
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this is a fantastic build!!Good flippin job ,man!After its all done,you will reap the rewards.
thanks buddy... :D
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Ok i just wondered about running the 6 puck on the street. Yet i think i'm going for the rigid hub. Do you know how much weight you removed? Thanks for the help.
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Ok i just wondered about running the 6 puck on the street. Yet i think i'm going for the rigid hub. Do you know how much weight you removed? Thanks for the help.
solid hub clutches are pretty noise...and they can be damn grabby...I have not driven a solid hub VW...but I have a solid hub on my cummins and it's pretty burly..
I just cut the ring off until it was flush with the dowel pin surface...pretty much took off as much as you can.....I never weighted it tho..sorry I wish I had...
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Ok well let me know how you like your setup works cause i'm probably gonna go the way you did.
On a side note i got a 2001 dodge 5spd thats gonna get a clutch. It's gonna be a farm truck what clutch would you recomend?
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Ok well let me know how you like your setup works cause i'm probably gonna go the way you did.
On a side note i got a 2001 dodge 5spd thats gonna get a clutch. It's gonna be a farm truck what clutch would you recomend?
I will let you know forsure...
I like haisley Machine clutches and I also like southbend clutches either one of those would be a great choice..I run a double disk haisley street drag in my cummins...I like double disk clutches...they make lots of single disk that hold lots of power...but I really like the DD clutches my self
but what clutch you you want is based off your HP goals and truck usage...if it's a stock farm truck you could get a single probably....but if you tow lots and want to add more HP now or later you ought to look at a DD.....I would probably get a DD clutch regardless...
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K sounds good the truck has a fuel box and other minor stuff. Acctually haisley is close to the truck in ind.
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got my new gauges installed too!!! 8)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0451.jpg)
Where can I get a guage pod like that?
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Where can I get a guage pod like that?
here you go buddy...
http://www.gaugepods.com/vw.html
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well mt gas relay base was not the same and not compatible at all :(
I found a plug and play pigtail/harness but I have had to order it so I made my own plug to get me by till it gets here....
glow plug relay base..
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/glowplug.jpg)
it's almost ready to start!!
I had a BRUTAL migraine today so I pretty much did not get anything done..just some odds and ends.
pic update tomorrow..... 8)
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well I did not make my goal I had to start it this week....I probably could have but I worked some other stuff on the car and not just the "get it started stuff"
I did most the glow plug wiring....I used Vince W's write up to get the idea on it but I went with a different style fuse block.
I have all the wiring hooked up to a VW style glow plug relay..then it's ran through the ford style relay and then to the fuse block, then to the glow plugs....
I have the wiring done except
glow plug light
temp sensor
fuel solenoid
problem is the glow plugs did not kick on when I tested them last night.
do I need to have the
glow plug light
temp sensor
fuel solenoid
wires hooked up to the glow plug relay in order for it to kick the glow plugs on???
here is my glow plug wiring
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0475.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0473.jpg)
I thought if the wires I have unhooked are left unhooked the glow plugs would still come on....but they would default time for 30 seconds or something???
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some pics of my water and oil supply lines..
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0484.jpg)
turbo coolant return line hooked into the old oil cooler line...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0480.jpg)
turbo coolant supply line..
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0477.jpg)
this is my "connectzilla" bonus points if you can tell what I made my oil manifold from :lol:
I have a few things hooked or will be hooked up there that why I have the manifold..OEM oil temp sender, OEM oil pressure sender, turbo supply..then I will have one extra spot for a incab oil pressure gauge or just a pressure checker spot for my shop gauge. (yeah I know I dont have the oil cooler hooked up in this pics....I still debating on if I should use the non thermostatic sandwich I have or ..just buying a new thermo version)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0476.jpg)
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I cut some of the lip off the front bumper so I could mount my intercooler on the bumper..
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0487.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0471.jpg)
this idea is Zukgod1 idea...another big thanks to him for all his help and advice with this build...
this is a dodge cummins fuel canister/water separator
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0481.jpg)
water drain
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0488.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0489.jpg)
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Oooo Ooooo Pick Me Pick Me!!!!
I know what the "connectzilla" it is..
What do I get if I'm correct?
-
new engine bay pics...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0467.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0470.jpg)
air filter tubing...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0469.jpg)
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how it sits now....
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0490.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0491.jpg)
turbo diesel badge replaces the "jetta GLI" badge :twisted:
thanks for the badge Zukgod1
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0492.jpg)
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I think I may need one of those Uinta Diesel Performace stickers.. :)
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Oooo Ooooo Pick Me Pick Me!!!!
I know what the "connectzilla" it is..
What do I get if I'm correct?
What? I dont get to guess?
:(
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i know what the connectzilla! is what is the prize?
also wow that really looks nice good job!! :shock:
but do you have a plastic baffel under the valve cover? i think you may need to get more upper and lower end ventilation and add a catch can!
if you don't have a baffel atleast under the V.C. i know what color that little filter is gonna be!
Duane
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I think I may need one of those Uinta Diesel Performace stickers.. :)
you bet buddy!!
I got red and black or red and white.....
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Oooo Ooooo Pick Me Pick Me!!!!
I know what the "connectzilla" it is..
What do I get if I'm correct?
What? I dont get to guess?
:(
sure you can guess!!!
I will give you a sticker if you guess right! lol
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splitter for air compressor hose fittings!
do i get the sticker?
:D
Duane
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i know what the connectzilla! is what is the prize?
also wow that really looks nice good job!! :shock:
but do you have a plastic baffel under the valve cover? i think you may need to get more upper and lower end ventilation and add a catch can!
if you don't have a baffel atleast under the V.C. i know what color that little filter is gonna be!
Duane
I will send you a sticker!! :lol:
yeah I do have a splash shield under my VC.......what kinda lower ventilation are you talking about??...I thought I could plumb the VC vent back to the lower block section?? or ???
I am fully open to ANY ideas on venting both top and bottom...
links? any good threads??
thanks for the help Duane 8)
Mark
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check Joe's out (rabbitGTDguy)http://vwdiesel.net/phpBB/viewtopic.php?t=16558
might help ?
thanks Duane
send sticker to;
K Duane Keaton
4275 S. 35th. st.
Greenfield , Wi. 53221
thanks i'm a weiner :shock:
L.O.L.
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splitter for air compressor hose fittings!
do i get the sticker?
:D
Duane
WINNER WINNER
PM me your address and I will send you a sticker.......you want red & white or red and Black????
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Nice car man.
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BTW I have been reading over my Bentley and I realized I posted exactly why my Glowplugs did not work!!!!
the GP relay gets its trigger from the 12v+ off the fuel sol...so since I don't have that wire hooked up the relay wont energize :oops:
I have this bad habit of looking for the hardest problem and then going easy problems last :oops:
diagnosis 101
1. start at easy most likely problem and work your way to the hardest
Next week she will run!!!!!
I hope...lol
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check Joe's out (rabbitGTDguy)http://vwdiesel.net/phpBB/viewtopic.php?t=16558
might help ?
thanks Duane
send sticker to;
K Duane Keaton
4275 S. 35th. st.
Greenfield , Wi. 53221
thanks i'm a weiner :shock:
L.O.L.
there's my address
my caddy is black
so red and white what ever you think will work with my caddy?
thanks Duane
P.S. what kind of sticker did i win?
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check Joe's out (rabbitGTDguy)http://vwdiesel.net/phpBB/viewtopic.php?t=16558
might help ?
thanks Duane
send sticker to;
K Duane Keaton
4275 S. 35th. st.
Greenfield , Wi. 53221
thanks i'm a weiner :shock:
L.O.L.
there's my address
my caddy is black
so red and white what ever you think will work with my caddy?
thanks Duane
P.S. what kind of sticker did i win?
well you won a real life Uinta Diesel Performance sticker just like the one on my strut bar.... :lol:
if you really want it I will send it out on Monday....
I guess I will send a red and white and a red and black so you can pick the flavor you like :D
thanks for playing.....lol
Mark
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check Joe's out (rabbitGTDguy)http://vwdiesel.net/phpBB/viewtopic.php?t=16558
might help ?
thanks Duane
quote]
great link!!! that gives me a REAL GOOD idea!!! I will post up my version soon...
thanks Duane 8)
Mark
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hey no problem ! ya know what they say! if the women don't find me handsom? atleast they will find me handy! :shock:
and thanks in advance for the stickers :D i know for sure i'd like to put red/white ones on the bottom of my doors on each side of my caddy doors!
you can send as many as you like? I got kewl stuff to put them on!
thanks Duane
P.S. let me know if you need shipping money?
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53 willys!!! Can we play for more stickers????
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G40 valve cover back from powdercoat
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/enginepics1.jpg)
been reading some threads on Vortex.....and am pretty sure this IS a G40 cover...Vortex says there is only one style G60 cover and the oil cap is on the passenger side...they say if you have an aluminum cast valve cover and the oil cap is on the drivers side it is a G40 cover.
I dont care either way...I bought this one as a G60 cover but....the G40 works better for the 1.6td with bumper mounted intercooler...the intercooler piping would cover the oil fill cap on the G60 cover the G40 works perfect.
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I thought it might be a good idea to link my DIY port and polish thread to my build up thread.
DIY PNP is kinda time consuming but it's not hard at all. 8)
http://www.vwdiesel.net/phpBB/viewtopic.php?t=15823&highlight=
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Here is what I was thinking of doing for a vent.
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MEWAX:IT&item=170261414507
Ever sense the Total Seal rings though I don't have enough blowby to worry about it, then where the hell would I put it?
It's already pretty busy under my hood.
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Here is what I was thinking of doing for a vent.
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MEWAX:IT&item=170261414507
Ever sense the Total Seal rings though I don't have enough blowby to worry about it, then where the hell would I put it?
It's already pretty busy under my hood.
wow great link!
I cant even build my own for that price!!
I'm gonna order one! thanks Dan
wish my new pistons did not come loaded...then I would have got some total seal rings...hopefully my blow by is minimal....
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That's what I was thinking as well.
Cant build one for $20...
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good job man
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it's not a g40 cover beaucause ,you'r cover dont have bypass
this is a g 40 cover(it's a picture of my g40 1989)
(http://img254.imageshack.us/img254/4750/imag0024ks3.jpg)
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That and the G40 has center bolts..
-
Since the G40 cover seems to have 3 center bolts, would it fit an AAZ head by any change?
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Since the G40 cover seems to have 3 center bolts, would it fit an AAZ head by any change?
nope!!! it won't work both ends of the G40 have half moon cut outs and only the AAZ has a half moon cut out on the pully side!
but a little fabrication anything will fit! :wink:
Duane
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well I guess Im wrong again.....all the vortex pic links are dead so I did not have good pics to compare to....I guess it is a G60 cover...
Zukgod1 came over last night and helped me get the car started!!!!! :twisted:
Man she idles REAL smooth!!!!
the VE IP pump cant suck fuel through my stock transfer pump tho....and the pump wont kick on cause the ECM has been pulled and the pump was triggered off the Gasser ECM.
so I got some rewiring to do today....
on the home stretch NOW!! :D
pics and maybe some vid later today.... :twisted:
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:twisted: :twisted: :twisted: :twisted: :twisted:
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Damn thing sounds sweet!!!
Hopefully he is out driving it right now..
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well I got it running and driving.......problem is when I pulled it out of the shop last night to drive it.
I go around the block 2 times...on the 3rd run the heater core blew open and filled my car with coolant :cry:
the other problem is it feels like I am not getting into 1st gear...the shifter is all the way over but it feels like 3rd when I take off...maybe my trans linkage is out of adjustment???
pretty bummed about it....I wanted to have this car done but now I gotta go back to my regular job...
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well I got it running and driving.......problem is when I pulled it out of the shop last night to drive it.
I go around the block 2 times...on the 3rd run the heater core blew open and filled my car with coolant :cry:
the other problem is it feels like I am not getting into 1st gear...the shifter is all the way over but it feels like 3rd when I take off...maybe my trans linkage is out of adjustment???
pretty bummed about it....I wanted to have this car done but now I gotta go back to my regular job...
Trans linkage is a pain in the ass to adjust without that little tool but we can get it.
The heater core is another story.
I don't want to bum you out more but that's not a fun job. Have to completely remove the dash so don't be reassembling anything up there right now.
I suspect maybe the necks got weakend when you replaced the hoses, they are famous for leaking after being messed with.
Good new is you have a guide, been there done that so no worries.
Let em know when you are going to start on it and I'll see if I can come help. Now that I've done it I don't think it's that bad but that first dash swap was nerve racking.
At least it runs so you are on the correct path. It's all the little things that seem to take up the time.
-
here is a few shots of the single round headlight conversion I did (smoked E-codes).....I made/converted my square headlight radiator support to a round.....it was a PITA!!
also you can see my intercooler piping...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0479-1.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0478-1.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0480-1.jpg)
adjustable intercooler bracket
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0481-1.jpg)
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well I got it running and driving.......problem is when I pulled it out of the shop last night to drive it.
I go around the block 2 times...on the 3rd run the heater core blew open and filled my car with coolant :cry:
the other problem is it feels like I am not getting into 1st gear...the shifter is all the way over but it feels like 3rd when I take off...maybe my trans linkage is out of adjustment???
pretty bummed about it....I wanted to have this car done but now I gotta go back to my regular job...
Trans linkage is a pain in the ass to adjust without that little tool but we can get it.
The heater core is another story.
I don't want to bum you out more but that's not a fun job. Have to completely remove the dash so don't be reassembling anything up there right now.
I suspect maybe the necks got weakend when you replaced the hoses, they are famous for leaking after being messed with.
Good new is you have a guide, been there done that so no worries.
Let em know when you are going to start on it and I'll see if I can come help. Now that I've done it I don't think it's that bad but that first dash swap was nerve racking.
At least it runs so you are on the correct path. It's all the little things that seem to take up the time.
thanks Dan!!
I have been calling around to find a ALL metal heatercore....are the replacements all metal or are they plastic like stock???? I HATE plastic heatercores!!!!
thanks for all your help Dan 8)
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I doubt you would have a problem with the plastic core Mark.
Once it's in there it wont get any abuse..
Pick one up and I'll do my best to come by and assist.
I was able to get that trans about 90% assembled last night so I HAVE to get that van done and out of my driveway ASAP..
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Looks great ! Where did you get your blue intercooler hose ?
-
Looks great ! Where did you get your blue intercooler hose ?
thanks!
the blue intercooler hose came from an Ebay seller..."just intercoolers" the guy who owns it is an ASS...but the prices cant be beat....I REALLY wanted Black or red hose for my project...but the price of the "just intercooler" kit was sooo cheap that I could not resist...if I wanted red or black hose it would have cost me a extra $100+ the ebay seller only has blue hose....
also check out siliconintakes.com...lots of good stuff on there and fast shipping too 8)
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Looks great ! Where did you get your blue intercooler hose ?
http://stores.ebay.com/Just-Intercoolers
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That looks SO perfect. I wonder how much that has increased in value... Invaluable!!!
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That looks SO perfect. I wonder how much that has increased in value... Invaluable!!!
thanks buddy! I'm pretty happy with the way it's turned out 8)
BTW if you want a sticker or two let me know :wink:
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new glow plug relay is on it's way my Deutz relay did not work right...
I also have a new heater core $45...it's at the shop...I will hopefully get this car ready by the beginning of next week.... :)
Dan I need your help adjusting the shifter linkage....I dont have the little VW shifter plate....do we need it???
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new glow plug relay is on it's way my Deutz relay did not work right...
I also have a new heater core $45...it's at the shop...I will hopefully get this car ready by the beginning of next week.... :)
Dan I need your help adjusting the shifter linkage....I dont have the little VW shifter plate....do we need it???
I don't have one either, we can get it adjusted.
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That's looking really good! Congrats!
BTW; I hope you will soon send pictures of your front bumper with the new I/C in place. Is it going to fit with the original 'big bumper'?
Interested since I have a similar intercooler for my Jetta too.
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http://www.vwdieselparts.com/forum/viewtopic.php?t=7676
The link within the link is broken.
Meaning the link over at vwdieselparts is broken.
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That's looking really good! Congrats!
BTW; I hope you will soon send pictures of your front bumper with the new I/C in place. Is it going to fit with the original 'big bumper'?
Interested since I have a similar intercooler for my Jetta too.
Thanks
yeah the IC fits just fine with the stock big bumper....I did have to do some trimming tho....but it is very minimal......looks stock IMHO
I will post some pics in the next day or so...
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VWCaddy's link is still good in that thread.
Here it is to save clicking.
(http://www.4crawler.com/Diesel/ForSale/Images/VWtool3285.jpg) This is the 150 DPI scan of the actual tool on Roger Brown's site. You should just be able to Right-click and Save As and print it out 1 to 1 on card stock, etc.
Andrew
thanks Andrew!!! that's sweet!.....problem is I cant get it to print the right size :oops: ....do VW dealers stock this tool?? is it spendy?
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Well I got the heater core out!! WHAT A PITA!!! I was getting WAAAAAY pissed trying to get it out with the dash in....I finally just pulled the whole dash out..it made it MUCH easier then...
I saw and read the heater box rebuild write up on vortex...my heater box foam was falling apart and rotting BAD...so I decided to rebuild it this week end..this is what it looks like right now. I still gotta cut out the foam sticker sheets...supposedly walmart selling all colors with sticky backs...I could only find the "assorted colors pak" with sticky backs....so I will have a black, red and blue door on my box! :lol: no biggie nobody but the people reading this will know..lol foam sticky back pak was $2.68.
here are the parts...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0486.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0487-1.jpg)
I also pulled the cluster out to do the gas to diesel tach conversion...problem is nobody has any info on modding the MFA style tachs :( I was kinda anticipating this so I bought a "parts diesel KMH Canadian cluster" form "Burn your money" I thought I might be able to mix and match some parts but the cluster I had was VDO/MFA and the diesel cluster I got from Tyler was motometer/non MFA
soooo I had to just swap the cluster housings..the parts cluster had a crack in the clear plastic.
at first I really wanted to keep the white face gauges I had.....but now that I look at the black I think I like the black better 8)
but now I gotta sale the white pyro and boost I just bought :(
so PM me if you want a smoking deal on some new white faced isspro gauges.. :D
old cluster..16v gas
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0451.jpg)
new diesel cluster with tach...I should probably get a MPH odo for it....but I'm kinda digging the KMH odo...it gives it a euro feel :lol:
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0484-1.jpg)
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The Parts Place sells the alignment tool.
That sticky foam works great for the floppy vents that always want to point downward,...
stuck to the end of the vent housing it provides enough friction to hold them aimed right where you want them.
-
couple pics of my heater box rebuild....
heater door with red foam sticker cut out and installed..
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0489-1.jpg)
bigger door blue and black sticker foam
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0490-1.jpg)
and the smaller defrost door..
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0492-1.jpg)
this foam sticker stuff seems to be real nice for the oem foam replacement...pretty cool trick...thanks to the guy on vortex who did the DIY..
heaterbox is going in tomorrow morning...then I gotta adjust the trans linkage and I hope to be good to go for awhile!! (yeah right lol)
I also ordered some LED dash lights...I hate how dim the stock cluster lights are
:x
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alignment tool (http://www.filefactory.com/file/458830/n/Alignment_tool3_pdf)
Here's a pdf. Print it to 8.5 x 11 and it should be correct (unless your printer is off).
The first page is from the page that Vince originally posted in that thread. The outline on top in red is cad drawn from the dimensions the page listed (it's a slight bit off maybe from the scanner?). The second page shows the scan of the actual tool and the discrepancy with the previous sheet that Vince posted.
I don't know how much the tool costs or where it is available.
Andrew
thanks Andrew!! I printed them out and it looks like it worked...BUT witch one do I copy?? the one with real measurements or the scan of the tool only??....I just want to get it right the first time so I wanna be sure.
thanks
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You sure on the LED's there??
I think once it's dark out they are plenty bright.
I have mine turned all the way down as the Autometer gauges lite up so much brighter than the cluster lights.
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You sure on the LED's there??
I think once it's dark out they are plenty bright.
I have mine turned all the way down as the Autometer gauges lite up so much brighter than the cluster
lights.
We will see about the LEDs ....the ones I'm getting are pretty much plug and play...its not that hard to change them..
I'm also kinda woundering if I should put a mph gauge in so they dont get freaked out when I get the title changed to diesel???
I'm gonna need the miles on the odo to match somewhat close to what the title says..
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You sure on the LED's there??
I think once it's dark out they are plenty bright.
I have mine turned all the way down as the Autometer gauges lite up so much brighter than the cluster
lights.
We will see about the LEDs ....the ones I'm getting are pretty much plug and play...its not that hard to change them..
I'm also kinda woundering if I should put a mph gauge in so they dont get freaked out when I get the title changed to diesel???
I'm gonna need the miles on the odo to match somewhat close to what the title says..
Hmm.
Ya probably not a bad idea at all. There should be some in the PnP I'll bet.
You could probably take the cluster apart there to get the MPH face.
I don't think it will matter though when it comes to licensing.
Them mileage can be explained " this cluster came with this engine"
Your title will be branded "Mileage in excess of mechanical limits" or something like that.
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**UPDATE**
Well I been driving the car a bit and I have been working some issues out...I still got a few to get right but the big ones are
1.keeps boiling coolant out..(3/4 way up on the gauge)
2.Transmission needs some shifter adjusting
3.Breather filter is blowing oil EVERY WHERE!!!!!!!(just like you guys said it would)
So I dont know why it keeps boiling over,,,I 90% sure the gauge is reading correctly..I did shoot the hoses with a lazer heat gun and temps were never over 201* on any part of the coolant system......I wounder if it's air pockets??....I even put a vacuum pump on the small bypass hose to try and get all the bubbles out.....it bubbled over like 3 times today....but just now when I drove it home it did not.
transmission is still a little out of adjustment...I made BOTH version of those tools and NONE of them made for the correct adjustment. :(
I ended up just doing it by feel...but now i went a little to far so I gotta adjust it back.
So you guy were right!! the filter I used for a breather is puking oil ALL OVER the place!! :evil:
so I was showing my dad and also telling him about those $100 billet old navy CCV filters and he said checker has a pretty sweet CCV with a Billet body, lid and hose nipple...he had one on his jeep valve cover so he showed me his and that's what I'm gonna get!! it's super pimp and the price cant be beat.
check it out!(I'm not 100% sure this is the same as my dads?? so wait until I post pics and part numbers for the one I know will be perfect for this car. I'm gonna pick one up tomorrow)
http://www.partsamerica.com/ProductDetail.aspx?MfrCode=SCT&MfrPartNumber=42795&CategoryCode=5001
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Congrats on getting it going! :twisted:
How old is the lid on your expansion tank? Sometimes they get old and won't hold pressure. If you can't pressurize the cooling system it will boil much sooner. Do all the hoses seem equally hot or are some areas hotter than others? Is the fan cycling on and off properly?
Pull the lid off the expansion tank when the car is cold and then start it up. If it builds pressure or you see a lot of bubbling when stone cold you may have a more serious problem.
I've never had a problem with air pockets on my MKII's. You results may vary though. My gasser has a cam and runs with advanced timing. The gauge can shoot up to 3/4 in the blink of an eye when sitting in traffic. It doesn't seem to bother it and there is certainly no boiling action.
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I've struggled with cooling problems many-a-time.
If you have a leak anywhere it will boil over.
If the tank is old and doesn't seal/work it will boil over (same with the lid as mentioned before)
If the rad fan doesn't turn on it will boil over.
If there is air in it anywhere it will boil over.
CHECK THE LID FOR THE RUBBER SEAL
sometimes it gets pushed back and you have to peel it back to where it's meant to be!!!!
don't waste money on a new cap if that is the problem!!!!
check that first!!! check that first!!! check that first!!! check that first!!!
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http://www.partsamerica.com/ProductList.aspx?PartType=116&PTSet=A
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http://www.partsamerica.com/ProductList.aspx?PartType=116&PTSet=A
whats that???
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Did ya click on it?
Your prob on your phone huh?
It's a link to rad caps.
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Did ya click on it?
Your prob on your phone huh?
It's a link to rad caps.
before it was link to checkers search...now your right it links to radiator caps...thanks Dan
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I've struggled with cooling problems many-a-time.
If you have a leak anywhere it will boil over.
If the tank is old and doesn't seal/work it will boil over (same with the lid as mentioned before)
If the rad fan doesn't turn on it will boil over.
If there is air in it anywhere it will boil over.
CHECK THE LID FOR THE RUBBER SEAL
sometimes it gets pushed back and you have to peel it back to where it's meant to be!!!!
don't waste money on a new cap if that is the problem!!!!
check that first!!! check that first!!! check that first!!! check that first!!!
Man I feel like an idiot!!! you nailed it Ed...I looked at my cap and the oring is all messed up!!!...it came off and the threads got trashed!
I got a new cap should be here in a few hours..
thanks Ed
Mark
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well I thought I had it figured out but I dont! :evil:
I am still burping out coolant even with a new cap :evil:
and now my oil dipstick is puking oil just like ARB's new engine!! :evil:
I'm pissed!
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hey 53 i got the stickers ! thanks so are these a company by you or something else whats the back round on them?
Duane
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small little up date..
problems..
1. still burping coolant out of the overflow :evil:
2. turbo coolant feed line is leaking(wrong fitting)
3. oil puking out of the dipstick tube
4. heater blower motor inop after heatercore change
5. coolant leak around oil dipstick(i think I got this one fixed)
6. tach is reading low at idle and maybe up top too?
7. bad control arm bushings
8.I think the rear motor mount is shot...are gli rear motor mounts hydro??
9. I'm sure I will find something for 9. :wink:
dang I just wanna drive this thing!! now I gotta wait till Tuesday so I can get the right turbo coolant adapter :( then i'm sure I will have some more issues to tackle.
*sighhhhhh* :(
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I did get my universal glow plug relay base yesterday!!
this a sweet way to wire the factory style glow plug relay for guys who want to keep the gas transfer pump and still run the VW glowplug relay..
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/GPrelaybase1.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/GPrelaybase2.jpg)
I picked it up from the local Smith Detroit dealer....part number on the bag 8)
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epic build thread, such attention to detail. Could we see some pics of the front with the FMIC behind the bumper?
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small little up date..
problems..
1. still burping coolant out of the overflow :evil:
3. oil puking out of the dipstick tube
4. heater blower motor inop after heatercore change
5. coolant leak around oil dipstick(i think I got this one fixed)
6. tach is reading low at idle and maybe up top too?
7. bad control arm bushings
8.I think the rear motor mount is shot...are gli rear motor mounts hydro??
9. I'm sure I will find something for 9. :wink:
:(
Did you get to sort any of this stuff out?
I may have some suggestions:
1) If you barely have gotten the car to temp, and it's forcing out coolant, then chances are the return hose is clogged. If your upper rad hose (with the split-off for the overflow tank) is USED, chances are the restrictor fitting in the line (the "mouse in the snake" right before the overflow tank) is clogged. You can drill it out and completely remove it. It really isn't that necessary. I bought a 1.6 ECOdiesel last summer that the guy thought had a blown HG. He would not drive it much since it would force out the coolant. I checked that fitting, and sure enough, it was clogged. Drilled it out, removed the remains, and it ran fine: never overheated again.
3) Oil puking out of the dipstick can only mean a pressurized crankcase. Somehow, you engine isn't breathing properly. Did you ever try the stock CCV valve? With new pistons and rings, I doubt it's blowby, but there may be a bit of excess blowby since the rings haven't seated yet.
7) The TT control arm bushings are a popular ubgrade (there's a thread here with the PN). They're solid rubber instead of perforated.
8) Trans rear mount is hydro, but they rarely go bad. The pass side rear mount is merely rubber. They go bad more frequently. When they do, you tend to get vibrations at certain speeds. It really won't cause idle vibrations unless it's really bad.
Let us know how it's going.
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epic build thread, such attention to detail. Could we see some pics of the front with the FMIC behind the bumper?
thanks for the nice words buddy....I need some encouragement these days...this VW is trying my patience...
yes I will grab some pics of the car today. 8) :lol:
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small little up date..
problems..
1. still burping coolant out of the overflow :evil:
3. oil puking out of the dipstick tube
4. heater blower motor inop after heatercore change
5. coolant leak around oil dipstick(i think I got this one fixed)
6. tach is reading low at idle and maybe up top too?
7. bad control arm bushings
8.I think the rear motor mount is shot...are gli rear motor mounts hydro??
9. I'm sure I will find something for 9. :wink:
:(
Did you get to sort any of this stuff out?
I may have some suggestions:
1) If you barely have gotten the car to temp, and it's forcing out coolant, then chances are the return hose is clogged. If your upper rad hose (with the split-off for the overflow tank) is USED, chances are the restrictor fitting in the line (the "mouse in the snake" right before the overflow tank) is clogged. You can drill it out and completely remove it. It really isn't that necessary. I bought a 1.6 ECOdiesel last summer that the guy thought had a blown HG. He would not drive it much since it would force out the coolant. I checked that fitting, and sure enough, it was clogged. Drilled it out, removed the remains, and it ran fine: never overheated again.
3) Oil puking out of the dipstick can only mean a pressurized crankcase. Somehow, you engine isn't breathing properly. Did you ever try the stock CCV valve? With new pistons and rings, I doubt it's blowby, but there may be a bit of excess blowby since the rings haven't seated yet.
7) The TT control arm bushings are a popular ubgrade (there's a thread here with the PN). They're solid rubber instead of perforated.
8) Trans rear mount is hydro, but they rarely go bad. The pass side rear mount is merely rubber. They go bad more frequently. When they do, you tend to get vibrations at certain speeds. It really won't cause idle vibrations unless it's really bad.
Let us know how it's going.
thanks for your help quantum!
1. I have tried EVERYTHING except drilling the mouse in the snake...
I have let it idle with the cap off till the fan kicks on and off a few times...then I put the cap on and waited for the fan to kick on some more..witch it did......problem is I STILL puke coolant out of the bottle.
it seems to ONLY happen when I drive it....I can idle it ALL day and it will not overheat...but when I drive it, it pukes coolant...pretty much every time.
I have put about 200 miles on it so far....but It still ends up being "low" after I drive it for a bit...even if I let it sit over night it still is "low" and it pukes out the overflow bottle no matter what...it seems to run warm too....it does not overheat with normal driving..but if I get on it hard it will overheat pretty quick......I am really at a deahead here...I just dont know why it's acting this way??
every hose on this car is brand new
new heatercore
new A/C radiator
new radiator cap
new water pump
new t-stat
I even disconnected the turbo coolant lines to eliminate the turbo...and it still pukes! :cry:
I also hooked up a hand vacuum pump to the "mouse" hose and sucked coolant through the system that way!!!! still no change :(
this problem is THE WORST!!! I really hate overheating issues :evil:
3. well I FINALLY fixed this oil leak....I had to vent the head AND BLOCK....I dont know why?? but soon as I plumbed the block into the top CCV section it stopped puking oil out the stick......
I should note that using the word "puke" may have been excessive...it was more of a very slow and slight ooze that only happened when freeway driving.
4. got the blower motor fixed......this is really bad but....
I had a dream about the wire/connector that I had forgot to plug back in....I went out the next morning and sure enough the plug/connector was there AND unplugged!! :lol: dreaming about VW's...this is getting outta hand!...lol
5. still have not found the coolant leak around the dipstick....I plan to get the car up in the air today...
6. tach still reads low..i think...but i've been busy with these other problems to check it.
7. I ordered ALL new suspension bushing and ball joints.(TT/R32 backs and stock fronts)
8. after reading up some more I found out the GLI I have has hydro mounts ALL around...the rear passenger side must be toast..I ordered one of those too...I checked the mount and yes it is bad altho it showed no signs of leaking?
the car runs better and better everytime I drive it.....if I can stop this coolant puking and running warm issue I will be a MUCH happier dubber....
pics later today.....
thanks for you interest and help quantum!!
cheers
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well I took the car out(AKA="oil spill") :lol: out for a cruise I stopped by the lake to snap some photos...I did not even wash it so be easy on me...if you look close you may be able to see some greasy finger prints on the paint!...lol I still wanna do a hardcore wax job with all 3 stages and restore the black trim..but that can come later...I gotta get the mechanical issues dialed in...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0494.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0502.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0499.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0498.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0508.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0510.jpg)
I still need to loom all the wires and finish hooking up my glow plug temp gauge...I also have a big nasty fitting on the head with my "test" oil psi gauge....i hate not seeing oil psi gauge so I have the test oil gauge from my tool box strung into the cab :lol:
*note* the coolant blown out all over my intercooler piping :evil:
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0507.jpg)
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looks good, lower that baby down a bit
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looks good, lower that baby down a bit
thanks...yes I want to lower it bad!...but I gotta get all these other issues worked out...
for the looks department I will be doing...
powder coated black STOCK BBS's
lowered(probably coilovers)
wax
redye the black plastics
tint
MK3 cupholder/center console
B pillar seatbelts
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How are you going about tint?
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I've struggled with cooling problems many-a-time.
If you have a leak anywhere it will boil over.
If the tank is old and doesn't seal/work it will boil over (same with the lid as mentioned before)
If the rad fan doesn't turn on it will boil over.
If there is air in it anywhere it will boil over.
CHECK THE LID FOR THE RUBBER SEAL
sometimes it gets pushed back and you have to peel it back to where it's meant to be!!!!
don't waste money on a new cap if that is the problem!!!!
check that first!!! check that first!!! check that first!!! check that first!!!
Man I feel like an idiot!!! you nailed it Ed...I looked at my cap and the oring is all messed up!!!...it came off and the threads got trashed!
I got a new cap should be here in a few hours..
thanks Ed
Mark
I'm really sorry that didn't fix it Mark :cry: :cry: :cry: :cry:
looks like you have bigger issues somewhere. Could be the HG didn't seal right? always a possibility.
I almost thought i'd earned a sticker with that one :cry:
I'm gonna get one! I'm determined! unless you already sent mine?
You said I had to post pics of my pre-existing stickers? or something. I just put the ARP's on last night after the hone 8) Therefore, the sticker went on immediately after. :wink:
I really hope you sort out the cooling. The only thing I can think of is a bodged HG because your hardware is all fine. I had SUCH a head ache I ended up changing the expansion tank and cap and almost all hoses. I have two left to change when I get more cash flow.
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Is there a steady flow of coolant through that small line going to the resevoir?
Is your vacuum pump plugged? Either into the booster or somehow setup so it isn't pumping air into the block unrestricted. That could cause oil to but shoved out the dipstick.
-
well I think I have a problem.....I drove it home tonight and when I got home I found /noticed coolant leaking from the head gasket!!
I'm beginning to think this IS a HG problem???
I dont know if I should just torque the ARP studs down some more or if I should just pull the head and inspect everything??
I torqued the studs to ARP specs...I think I went about 5ftlbs over spec...and I did NOT do a warm up re-torque either...should I have??
if the HG is leaking..should I go metal?? new fiber stock specs? new fiber over torqued?? if so how much??
this sucks!!!! I have not been beating on this engine at ALL..I have been very nice...expect for the one time I hit 20psi boost...I did not even realize I was boosting so high till the last second...but since then I have only been 10-12psi tops.....
HG??
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Headgasket is what I've been suspecting all along. A worse suspicion is a crack either in the head or block.
Did you do the test I outlined in my last post?
Andrew
this sucks!!!
I did not do the test you described yet....I plan on going out and doing it here in just a few mins now that it has sat over night........I'm pretty sure the HG is leaking tho. :cry:
i'm BUMMED!!!!
now should I buy a metal headgasket? and make it fit??
I have pretty much zero faith in the fiber gasket now...
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I'm sure he will reply but I'm almost positive the head was COMPLETLY gone through, pressure tested, valve grind etc etc.
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The oddity with the oil out the dipstick might be explained by crankcase venting issues. It could also point to combustion gasses entering oil the crankcase. Odd how venting the block helped so significantly as the block is connected to the head by several large drains.
Did you ever get the head pressure tested? How about magnaflux on the block?
If it were me I'd first do the outlined coolant pressure test. If it tested positive for pressure I'd pull the head and have it pressure tested. I'd carefully inspect the gasket, hoping to find evidence of leakage. With the head off I'd carefully inspect cylinder walls for any hiding cracks. Check the head for flatness. If everything checks out, then decide whether or not you want to go for the metal headgasket. Put it all back together and check.
Andrew
well it's true the HG must be leaking.....55 seconds=pressure in my expansion tank!!
*** I am so pissed about this!! :evil:
the head was pressure tested and had been completely gone through....
I think I might try torquing the studs a little more and see if it will reseal????? it's easier then pulling the head...
i'm so bummed about this...I dont think it was something I did...I have installed 100's of HG's and never had this kinda problem..but this is my first VW HG....
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wish I would have gone with a MLS gasket from the get go!!! :evil: :cry:
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WOW. Nice pictures!
:shock:
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I'm sure you'll get it worked out. It's just a hiccup.
Andrew
That's right. Hold your breath Mark. Works for me. :lol:
Seriously though. At least once you get it sealed up you'll know how to work on any part of this car.
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I'm sure you'll get it worked out. It's just a hiccup.
Andrew
That's right. Hold your breath Mark. Works for me. :lol:
Seriously though. At least once you get it sealed up you'll know how to work on any part of this car.
hey wait!!! I just put this car together from scratch!!....I already know how to do that...I just wanna drive it!...lol
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Good point!
-
Good point!
i know what you mean tho...I am learning a lot about vw's thats for sure...
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I'd retorque the head first. Look at it this way: you haven't overheated it since the rebuild have you? So, the head is fine (assuming it was good to begin with), and the block is fine, so retorque the head gasket. What's the worse that could happen? You have to replace the gasket anyways if it turns out to be bad, and on the bright side, you won't need to replace the head bolts, since the studs are reuseable.
As far as the torque procedure: You do the cold sequence, warm it up to temp, then turn 1/4 turn.
Later on, if you see some seepage from the gasket, you can retorque an additional 1/4 turn at 1000 miles. Some claim the new gaskets don't need this last step. If it's not leaking, then Jack at VWdieselparts says you can skip it. Since your head studs can handle the extra turn, I wouldn't rule out the last 1/4 turn.
I think you just need to finish the sequence and you'll be fine. I'm pretty sure those ARP head studs aren't even maxed out. The old strech bolts finish at about 100-120 ft-lbs once they're fully torqued. If I'm not mistaken, the final torque value listed for the ARP studs is significantly less, and they can take a lot more stress.
Unless you're running high boost values, I'm not sure you need to try to retrofit the metal HG.
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ARP's spec=80 ftlbs
What I TQed them=85 ftlbs
re-toque=????90 ftlbs???95 ftlbs???
I ordered a MLS gasket for it today.....so either way it's getting torn back down sooner or later.....I dont wanna worry about HG's anymore :evil:
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Could be the HG didn't seal right? always a possibility.
The only thing I can think of is a bodged HG because your hardware is all fine.
"Did I earn a sticker? :oops: ", squeeks the mouse in the corner.
DO not re-torque. Sweet jesus. Perhaps check them? don't go to 95...
just my 2 cents. But seriously, I totally called that HG 8) . But it does suck man :( I don't see the point in spending the cash of ARP's and not using a metal HG.
(I can't believe I was actually right about something. I always thought I was useless and annoying on this forum. I'm amazed you guys don't tell me to shut up!)
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Could be the HG didn't seal right? always a possibility.
The only thing I can think of is a bodged HG because your hardware is all fine.
"Did I earn a sticker? :oops: ", squeeks the mouse in the corner.
DO not re-torque. Sweet jesus. Perhaps check them? don't go to 95...
just my 2 cents. But seriously, I totally called that HG 8) . But it does suck man :( I don't see the point in spending the cash of ARP's and not using a metal HG.
(I can't believe I was actually right about something. I always thought I was useless and annoying on this forum. I'm amazed you guys don't tell me to shut up!)
haha yeah I did not want to belive it was a HG so I kinda kept thinking "no it cant be"...you nailed the radiatopr cap and the HG Ed!! your getting good!! nice job!!
I was talking with zukgod1 about the possibility of a bad HG just last week...we both wanted to believe it was something else and tried to come up with other reasons.......but nope....
the reason I went fiber and studs was I thought I would/could get much more life and boost with studs and fiber vs fiber and stock bolts....
I REALLY wish I would have MLSed it from the get go!!!!
I just felt like the oil cap rubber trick would/could be unreliable....now look at me with my super reliable fiber HG :roll:
o well least its not a 6.0 power stroke ford head gasket!!! :lol:
I think I may just tear it apart tomorrow and wait for my MLS to get here...even if I did re-torque it I would still worry about it lasting now that it has been leaked past before...
bad-luck=me :(
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I don't know of anyone that has had a fiber gasket go bad that fast.
,... but I hope it's the head gasket.
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Sigh, there there Mark.
Just think, after all this freakin' grief you have a sick ride now. (will do when you put the new HG on that is)
make a check list before you tear into it. I forgot about the oil return line once and was struggling uselessly like a moron standing on the strut and rad mounts trying to lift the head off. OH, the oi return is still on there. ooops.
Gosh this thing feels light now.
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I don't know of anyone that has had a fiber gasket go bad that fast.
,... but I hope it's the head gasket.
ugh!!! I dont even want to think about a cracked cyl wall or something else!!!! I had all that checked before rebuild...so hopefully I'm ok????
it does make me nervous tho....the HG should not have failed so fast and it makes me think it's something else major :cry:
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DO not re-torque. Sweet jesus. Perhaps check them? don't go to 95...
just my 2 cents.
Yeah, here's where people get a bit nervous, and torque specs get a bit screwy. In the ARP instructions, there should be 2 different torque specs based on what lube you use.
The bolt specs for the OEM stretch bolts is based on a thin film of light oil (usually applied to the bolts at the factory).
In the latter case, I've often gone over the bolts with my torque wrench (after all the torquing procedures), and I consistently get a final value of about 105-110 ft-lbs, and I occasionally torque them a bit more if I feel the need, but that's with TTY and I'd feel if it was approaching the danger zone. It's extremely frustrating that VW does not provide an actual final torque value like many other manufacturers, especially since we all KNOW that VW didn't even follow their own stupid instructions when they built the cars in the first place (really did they 'drive' every motor 1000 miles and retorque, or implement a practice that would be equivalent? I doubt it).
In any event, how do my observed final torque value compare to the ARP specs? I'm not sure, because I don't know what lube you used, and how it compares to the stock figures that I've noted over the years. I personally think 95 ft-lbs is a safe place to start and see what you get. My sentiment is this: if you have to replace the gasket anyways, why no try to retorque it and see what happens. My rationale in this case is as follows:
1) I'm assuming the head was straight and crack free when installed, the same goes for the block.
2) It sounds like the motor hasn't even been run much, and, by all accounts, has not "overheated". It showns symptoms of an overheat, but the motor does not seem to have been overheated. So, the head is not warped, and tightening the bolts will only work to seal the gasket better between two flat surfaces.
3) Aside from the one time when the owner hit 20lbs of boost(!), it really hasn't been run too hard.
So, given those factors, it seems that the only possible reasons for the blown HG so early in the game is either
1) Faulty gasket: I kinda doubt this one
2) Too much boost: a distinct possibility. But if the gasket were properly torqued, one would assume that the gasket could hold up for that brief moment of high boost.
or
3) The HG was never torqued down enough, and the extra boost that one time was enough to blow it, OR, it wasn't tight enough for even normal operation (we'd have to know if it was puking coolant BEFORE it was pushed to 20 PSI).
Given those parameters, I'd speculate option 3: the HG wasn't torqued down enough: whether that be for normal operation, or high boost levels. Especially when 53willys noted that it would idle all day and not boil over, but when run, it would spew. This indicates a excessive boost blow-by into the coolant system.
A little seepage and retorque is fine, so long as you are certain that there are not other problems in the head/block at noted by Andrew. Sooner or later, you'll have to pull the head. My view is, might as well try to see if you CAN'T get it to run right with the fiber gasket that's on there, and have the MLS as a safe back-up.
Just my $0.02
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well I dont think it was me and installer error...I did this HG torque sequence BY THE BOOK...its not hard...I have done ton and tons od Deutz 4cyl diesel HG's at my other job...I know how it works..
I followed ARP's TQ specs from the studs install sheet....
80ftlbs WITH ARP moly lube....the only thing I did different was I went to 85ftlbs....I highly doubt my extra 5ftlbs is what killed the HG..
I kinda think it has been leaking from the get go.....I blew the one hose I did not replace and I blew the top off my heater core too!!! this was on the first test drive...
my TQ wrench is working too....it's a BRAND new digital snap-on wrench....it's a flipping $700 wrench!!! it better be right!
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I followed ARP's TQ specs from the studs install sheet....
80ftlbs WITH ARP moly lube....the only thing I did different was I went to 85ftlbs....I highly doubt my extra 5ftlbs is what killed the HG..
I kinda think it has been leaking from the get go.....I blew the one hose I did not replace and I blew the top off my heater core too!!! this was on the first test drive...
my TQ wrench is working too....it's a BRAND new digital snap-on wrench....it's a flipping $700 wrench!!! it better be right!
Yeah. I doubt it was a manufacture error, or an installation error. My suspicion is that you had too much boost from the start. Are/were you running boost at idle? That's the only way I could see the HG blowing from the start, unless you had the boost too high, and really got into it from the first start-up.
It may not have been excessive boost by most standards, but if the bolts could have used a little extra torque, and your just went beyond what the bolts could handle, then perhaps it was "the perfect storm". I'm still not entirely sold on the ARP torque specs. If I'm not mistaken, they use the same specs for gasser and diesel heads don't they? Or are the bolts diesel-specific with their own torque values?
Anyway, good luck on the MLS retrofit. Too bad you didn't have a hydro block and head. I guess it would be a bit easier. It seems like someone here did the MLS retrofit and used silicone or something to block the oil retrun passage. It was holding up after several months. I'd love to see an aftermarket manufacturer make the MLS for the older diesels. Hell, I'd spend $50-100 just for the piece of mind.
Good luck!
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Hell, I'd spend $50-100 just for the piece of mind.
Good luck!
Wouldn't we all?
The MLS gasket even getting a good deal is $60.00 and thats the AAZ gasket so to have one made to our specs for the solid lifter block would be closer to $150.00 I bet and we would have to have prob 20 made at a min.
Someone started a tread a while ago on this very subject.
I think Kinetic (sp?) will make just about anything you want but dayum!! $$$
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Hell, I'd spend $50-100 just for the piece of mind.
Good luck!
Wouldn't we all?
The MLS gasket even getting a good deal is $60.00 and thats the AAZ gasket so to have one made to our specs for the solid lifter block would be closer to $150.00 I bet and we would have to have prob 20 made at a min.
Someone started a tread a while ago on this very subject.
I think Kinetic (sp?) will make just about anything you want but dayum!! $$$
that was me who started that thread....
it was a 150 gasket min!!!!
http://www.vwdiesel.net/phpBB/viewtopic.php?p=118528&highlight=#118528
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I knew it sounded familiar..
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I knew it sounded familiar..
if it was 20 min....I would do it myself and then just sell them myself....but I cant front that kinda cash........
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$13500.00 for 150 gaskets :shock:
Good thing I'm sitting down.
Look at your cell phone Mark.
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I think I found out what I am gonna do for the MLS mod....
forum member "AudiVWguy" sent me a PM telling me how he modded his MLS...to me his mod seems like it would be the most reliable of all the mods...
here are his instructions..
I've got the same setup. My concept was to use a piece of the original fiber gasket to use in the hole. My thinking was its a neutral material for thermal expansion. I made it fit extremely precise. The material can be filed for a perfect fit. The next thought was to put a light coat of oil resistance gasket sealer using a toothpick. They make some that has good temp resistance.
If I was to do it again I would try the sealer they use on the aluminum oil pans on VW's, could me superior stuff. Anyway, its important to let it dry some, maybe 1 hour plus, cause its important to have it semi cured but not enough so it can still squish out and seat perfectly. Torque the head and make sure you use ARP's special grease, otherwise they said different lube will have a different torque specs.
(http://i256.photobucket.com/albums/hh177/AudiVWguy/TURBOCADDY007.jpg)
(http://i256.photobucket.com/albums/hh177/AudiVWguy/TURBOCADDY019.jpg)
(http://i256.photobucket.com/albums/hh177/AudiVWguy/TURBOCADDY006.jpg)
(http://i256.photobucket.com/albums/hh177/AudiVWguy/TURBOCADDY005.jpg)[/quote]
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Yeah. I think I'd rather pay $90. Maybe someone should email FEBI or Reinz and give them a head's up.
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Another + on the MLS gasket is you can drill the block and head for the steam holes that are not there for the reg fiber gasket.
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Another + on the MLS gasket is you can drill the block and head for the steam holes that are not there for the reg fiber gasket.
dan can we do this with the block in car still put together??
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I've had the same thought before. I'd be sorely tempted to enlarge the return hole so that the seam is not in the middle of the coolant channel. I would then cut the plug to fit.
Andrew
so your saying you like this style mod...but think the hole in the fiber plug needs to be enlarged??
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Another + on the MLS gasket is you can drill the block and head for the steam holes that are not there for the reg fiber gasket.
dan can we do this with the block in car still put together??
I don't see why not Mark.
Would just run the pistons to TDC and plug the coolant ports around it then use a grease filled drill bit.
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Not exactly what I was saying. What I meant was that I would have more faith in it if the large hole in the metal gasket was made even bigger so that the perimeter of it extended around the coolant channel in the head and block. Then if the plug was made to fit closely it would be a complete seal of the coolant hole rather than have the seam of the two gaskets run through the middle of the coolant hole. I don't know if there is enough gasket between the coolant channel and the cylinder for that, tho.
Andrew
I get what your saying and that makes good sense. I wonder though even if there was enough material there to remove if the MLS and fiber would compress differently causing un even pressure on the surrounding gasket surfaces?
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Not exactly what I was saying. What I meant was that I would have more faith in it if the large hole in the metal gasket was made even bigger so that the perimeter of it extended around the coolant channel in the head and block. Then if the plug was made to fit closely it would be a complete seal of the coolant hole rather than have the seam of the two gaskets run through the middle of the coolant hole. I don't know if there is enough gasket between the coolant channel and the cylinder for that, tho.
Andrew
yes VERY good idea....I will have to see what I can do when I get the gasket in hand....
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well I retorqued it today...this is what I did
block heater was one all night so everything was warm...
torqued studs to=90ftlbs(some pretty loose studs I might add)
then I warmed the engine to op temp..
retorqued studs=95ftlbs
then went back trough the pattern and did
100ftlbs... :shock:
took it for a drive I railed on it pretty hard!! it ran GREAT!! took it to 20psi and she was just a shining!!!
8) :D
got home never got hot at all....I thought I had it until I popped the hood and saw coolant still seeping from the head and block...(right under the top radiator hose outlet...
guess I will pull the head and wait for my MLS...least then I can inspect it all and make sure nothing else is wrong..
NOTE If a guy is using fiber gasket I would recommend a retorque after a day or so.....I wounder if I would have retorqued sooner if it would have held??
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Hmmm.
So, it didn't puke out the coolant reservoir???
I'd say that you're almost there, or you've solved the problem
Are you sure it's leaking out of the HG, or is it just running out of the coolant flange gasket and dribbling onto the HG where the notched tab is? I had that problem on a recent rebuilt. The fiber gasket was so ***ty, it seeped coolant out and it collected on the HG tab. I thought the HG was blown, despite the fact that there were no symptoms of a blow out.
I see your car has the aluminum front flange, some of which used that fiber gasket. I'd look into it before/while you're getting ready to pull the head for the HG. Basically, I'm trying to be upbeat here, but also relying on the evidnce. If you ran the car hard, and it didn't force coolant out of the chamber, then it wasn't bulding pressure via lost compression into the cooling system. So, you seem to have resolved that issue. That means at least PART of the HG is sealing properly after the retorque.
I guess it could still leak OUT of the HG, but the flange is a convenient place to look in order to rule out all possible option while you figure out how you'll actually mount the MLS gasket.
Again. good luck!
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well it did puke some coolant from the looks of it...but it seems like it was less then before....I think it is still leaking slightly??
yeah I checked the top hose flange a few times to make sure it was not running down...the flange is dry as a bone :(
o well....least HG on these engines are easy! worst part will be getting to the turbo bolts!
maybe I will get some studs for that while I am at it?.?.?.?
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well I got the head off.....the hg was blown in a few spots!!!!!! :cry: :shock:
dang fiber gaskets!!!
now I'm waiting for myke to call me back so I can get a MLS for it!
dang fiber!!!
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Yeah, those fiber gaskets are donkey sh*t and nobody should use them :cry: Surprisingly mine was intact, though, when I opened up my 1.6.
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Yeah, those fiber gaskets are donkey sh*t and nobody should use them :cry: Surprisingly mine was intact, though, when I opened up my 1.6.
yeah I knew they are crappy...but lots of guys have had some ok luck...least I thought.....I was worried about the MLS mod...but if I cant even get 200 miles on my car and the HG is blown in at least 2 spots..then I dont wanna mess with it, I will take my chances with the MLS mod...
talked to Myke my gasket is on it's way! 8)
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Heres what the plug looks like that I showed you earlier. This is two years later and about 30K on it so far.Currently I am installing a Performance Diesel SuperPump and new injectors. As you can see the gasket sealer has worn away from washing the engine, but still no leaks.
(http://i256.photobucket.com/albums/hh177/AudiVWguy/IMG_1672.jpg)
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Heres what the plug looks like that I showed you earlier. This is two years later and about 30K on it so far.Currently I am installing a Performance Diesel SuperPump and new injectors. As you can see the gasket sealer has worn away from washing the engine, but still no leaks.
thanks for the pic buddy!!!! and I hope you dont mind that I posted pics of your mod...I feel it's good info to get out there..it seems like a great way to mod/run the MLS gasket...
Is that coolant seeping in this pic???? kinda looks like green coolant??
(http://i256.photobucket.com/albums/hh177/AudiVWguy/IMG_1672.jpg)
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Nope, being obsessive-compulsive every seventh time I open the hood.
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well I got some more parts to install...
I bought all new control arm bushings to rebuild the arms
I read about lots of guys who had poly bushing fail pretty fast...i will be driving this car everyday and I dont want to tear the arms off every other year to replace poly arm bushings so I went with the R32/Audi TT rears and Stock fronts....
I also picked up some ball joints, tie-rod ends, new hydro rear engine mount and I also picked up a poly sway bar bushings....I was thinking the sway bars would not wear out as fast as arm bushings?? so I thought I would try them...I may just go back to stock if these dont hold up.
since I was paying shipping I figured I would grab some of the rear axle bushings inserts....they are cheap so I figured I would give them a try...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0511.jpg)
finally found a Turbo Volvo at the wrecking yard with a oil cooler and T-stat sandwich adapter....I picked it up for $15..it came with the stock lines cooler and T-stat adapter plate.
it had some oil on it so I pressure checked it last night to make sure it was not leaking...it passed the test...no leaks 8)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0514.jpg)
maybe I will get lucky and my HG will show up today so I can install it this weekend!....fingers crossed :D
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Looking good!
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thought I would post a couple pics of my waterjacket mod...(sorry for the low quality..I just snapped the pics with my phone)
taped off the head to keep any shavings out..I just used green painters tape..
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/waterjacketmod1.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/waterjacket2.jpg)
tape removed...1/8" holes drilled..
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/waterjacketmod3.jpg)
since I had the head off I decided to peen the prechambers some more...I only penned them in 2 spots the first time..but I was still kinda scared they might drop so I gave them some more peens...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/waterjacketmod4.jpg)
shot with the 1.9AAZ MLS gasket on...I'm not using the 1.9AAZ now tho..I'm getting a custom made MLS gasket for the 1.6 CY,ME,MF
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/waterjacketmod5.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/waterjacketmod6.jpg)
now I gotta wait 2-3 weeks while my gasket is made
:(
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Well at least when you do get it back together you know it will be good.
I'm concidering having you get me a 1 notcher so I have one for next time....
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Well at least when you do get it back together you know it will be good.
I'm concidering having you get me a 1 notcher so I have one for next time....
wait I thought you needed 3 notchers?? on your engine?
is this for your spare engine??
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I originally used a 3 notcher because of the fuel I was running but after I installed the new rings i decided to go with the correct gasket for the protrusion I had which speced out to be a 1 notch.
So ya, I need a one notch.
My other engine a a full hydro engine so I will be able to use an AAZ gasket with no mods.
Maybe when it gets to that point I'll need a 2 notcher and I can buy the one you just bought from Myke to help ya recoup some of your costs.
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I originally used a 3 notcher because of the fuel I was running but after I installed the new rings i decided to go with the correct gasket for the protrusion I had which speced out to be a 1 notch.
So ya, I need a one notch.
My other engine a a full hydro engine so I will be able to use an AAZ gasket with no mods.
Maybe when it gets to that point I'll need a 2 notcher and I can buy the one you just bought from Myke to help ya recoup some of your costs.
thats right..I forgot you did that...I would love to sell you my AAZ 2 notch...let me know when your ready for it....it's gonna be in Thailand for the 3 weeks tho...lol
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Well I don't see me getting to the other engine within that time frame so no worries.
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well my gaskets still have not even made it to gasketstogo!!! the dang protesting that has been going on at the Bangkok Thailand airport has been holding up my mail....lucky for me the protesting ended yesterday!!!
hopefully I hear something this week.......the guy in Thailand(john) has been great so far..he "skype" me and told me all the problems and has been real easy to deal with. :D
man I really wanna get my car going!!
I'm eyeballing some coilovers for it right now.....xmas to myself?!?!?! :oops: :lol:
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I'm eyeballing some coilovers for it right now.....xmas to myself?!?!?! :oops: :lol:
FK's man!!!!!!!!!!!!!
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Why did you opt for a custom gasket opposed to the aaz one?
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Why did you opt for a custom gasket opposed to the aaz one?
I just dont like the idea of using oil filler cap rubber or sealer and old fiber gasket to patch the hole on the AAZ MLS gasket....I know lots of guys are running it with no problems...but I was just not completely sold on it, so I looked for a better option...it may end up costing me 2x as much as a AAZ mls gasket..but the piece of mind will be worth it to me.
I even had them make my new 1.6 mls gasket WITH the extra AAZ cooling holes 8)
I just wish they would hurry!!
:?
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53 willys, are you running a hydraulic or solid lifter engine?
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He has a solid lifter engine.
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I really can't wait to see how the gasket from gasketstogo work out. I'd be up for 2 or 3 if they are a success.
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I really can't wait to see how the gasket from gasketstogo work out. I'd be up for 2 or 3 if they are a success.
yep...Dan knows..I bought my engine from him!
I too am REALLY excited to see how this gasket turns out...I'm going crazy waiting..
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Great pictures!
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Ahhhh right you have a mechanical block i understand now.
I was like ... blocking the hole? what are you on about. Oh, mechanical lifters... :P
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I still can't believe the stock head gasket blew out that fast.
Put another fiber gasket in there so you can drive it while waiting for the special gasket,... they're cheap.
Just to satisfy my curiousity :D
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If you were closer i'd give you the fiber one i ordered by accident. I pad 15$ for it. It's a three hole no-name. :P
According to google earth you are 1,572 km away (15 hour drive)
Wow that huge salt lake is kinda neat :P :oops:
I've always wanted to snowboard in Utah :oops: :oops: :oops:
After fooling around on google earth around Utah i've decided what once my car is running again im going on a road trip to salt lake city and to utah lake. (after this ski season is over :P i got a season pass at a local hill :lol: )
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Come on down!
We would be glad to show ya around..
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I still can't believe the stock head gasket blew out that fast.
Put another fiber gasket in there so you can drive it while waiting for the special gasket,... they're cheap.
Just to satisfy my curiousity :D
I know HG are easy to change....but I'm not going to put a fiber back in..just to pull it back out in a couple weeks to put my MLS on..I dont need the car that bad :oops: :lol:
I will NEVER run a fiber gasket again on this car :(
I'm pretty sure if I would done a proper retorque I would not have blown it so fast...but I'm wanting some big reliable boost numbers and I know fiber will not/can not be reliable with high boost everyday...I really think my problem was the lack of retoruqe..lots of guys run pretty big boost on fiber..shoot that was half the reason I ran fiber and ARP's...I read about lots of guys having no problems......just make sure you retorque....warm engine with no coolant pressure on the system....let engine cool...retoruqe...drive happy :lol:
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If you were closer i'd give you the fiber one i ordered by accident. I pad 15$ for it. It's a three hole no-name. :P
According to google earth you are 1,572 km away (15 hour drive)
Wow that huge salt lake is kinda neat :P :oops:
I've always wanted to snowboard in Utah :oops: :oops: :oops:
After fooling around on google earth around Utah i've decided what once my car is running again im going on a road trip to salt lake city and to utah lake. (after this ski season is over :P i got a season pass at a local hill :lol: )
thanks for the offer Ed!....but I'm done with fiber gaskets!
come on down!!!! we would love to show you around....and yes bring your snowboard too!! this state is great for boarding!
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How could i pass up such an offer!
Thanks both of you :)
You will hear from me :lol:
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Merry Christmas everybody!!
I just got a nice Xmas gift from Thailand!!(pic only, the gaskets ship today)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/VWDiesel.jpg)
woot woot :lol:
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Since nobody else knows what that valve cover came off of, allow the n00b. :lol:
Yours:
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0433.jpg)
Euro Spec Golf 3 GTI 2.0 8v. Engine code AGG. (What Europe got instead of the ABA.)
(http://www.volkswagenspares.com/UserFiles/Image/golf%202l%20gti%20under%20bonnet%20(Custom)%20(2).jpg)
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well there we have it!!! nice job!!
I do like this cover better then the G60 since the oil cap is flipped...this way it does not interfere with my intercooler piping.
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I wonder if that square breather thingy would work on 1.6 / 1.9 diesel head... That would look much more modern than the hockey puck which I would scrap in a minute if it wasn't so damn necessery...
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You get this thing back on the road yet?
You have had 5 days now not counting the date you received the gasket.
Quit screwing around already!! :lol:
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You get this thing back on the road yet?
You have had 5 days now not counting the date you received the gasket.
Quit screwing around already!! :lol:
still no gaskets :cry: the pic above is from gaskets to go..John sent that to me to show me they are done...but he was JUST barely shipping them on the 25th..so it will be a few day still...
I did not really expect them to be here this fast...hopefully by the end of the week?? :twisted:
things to do when I get my MLS
1.install Drive pressure Gauge
2.install oil psi gauge
3.install water temp gauge
4.install new MLS gasket
5.BOOOOOOOST :twisted:
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6.Smile
7.Enjoy beverage.
:wink:
NICE those are excellent additions to my plan of action!!! 8)
thanks
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Its not done until you have the Smoke ticket to prove it!
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sigh......
my MLS is still in route :cry:
so I started to put my other gauges in and move my stereo down to the ash tray
cheap CD player from my old beater
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0537.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0538.jpg)
42 draft gauge pod..nice piece!!
drive pressure, coolant temp & oil psi..these isspro gauges match the OEM dash PERFECT!!!! looks really sharp if I do say so myself :P
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0539.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0540.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0541.jpg)
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nice! :wink:
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Very nice instrument setup.
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I like your wiring harnesses. Did you make them or did the come with the insturments ?
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Isspros's are just sweet gauges that come with all that nice wiring.
Good stuff right there.
Mark, what are you doing with the A Pillar gauges? Changing them over to the BLK face ones?
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Isspros's are just sweet gauges that come with all that nice wiring.
Good stuff right there.
Mark, what are you doing with the A Pillar gauges? Changing them over to the BLK face ones?
yeah I wanna change them to black with white needles to match....I will probably post them on the comp D...white faces go like hot cakes over there.
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thanks gents!!
the wiring is STOCK isspro..they come with separate amplifier boxes..so they have built in harnesses.
the lighting still needs to be wired..the wiring in the pics is just the power and signal for the amplifier boxes.
so water temp and oil psi are electric...the drive pressure gauge is mechanical.
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Those gauges are great. I may end up using them as well. What color do they light up?
Also, could you please explain exactly what "peening" is?
I've heard of "shot peening" before, but I've never had explained to me. I assume it's used to repair cracks in metal? :?:
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Those gauges are great. I may end up using them as well. What color do they light up?
Also, could you please explain exactly what "peening" is?
I've heard of "shot peening" before, but I've never had explained to me. I assume it's used to repair cracks in metal? :?:
the isspros I have light up green.....like stock..
since I had the head off I decided to peen the chambers some more...I only penned them in 2 spots the first time..but I was still kinda scared they might drop so I gave them some more peens...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/waterjacketmod4.jpg)
it's kinda hard to see with my bad phone pic...but the small round "dents" around the prechambers are the "peening"
basically you are just using a pointed punch to smash the prechambers into the head...
clear as mud???
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Hey Mark,
I noticed your screen name on here and recognized it from the DTR forum... I used to post on there pretty often in the 3rd gen section when I had my '05. Who would have guessed you were a vw diesel freak too!
I read through a few pages of this, and man you really did a nice job on the conversion! Nice find on that GLI too! I should have picked up a GLI or something nice and done that instead of the '85 jetta I did. Every diesel Jetta I see for sale is always a worn out pile! There are some nice gas ones that are real survivors though.
I'm back around on here again as I scored volvo with a D24T... I should be sounding like my cummins here shortly! I was almost thinking of sticking some "C" badges on the front fenders just to mess with the local truck guys...
Just wanted to drop in and say good work.
Jason
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Hey Mark,
I noticed your screen name on here and recognized it from the DTR forum... I used to post on there pretty often in the 3rd gen section when I had my '05. Who would have guessed you were a vw diesel freak too!
I read through a few pages of this, and man you really did a nice job on the conversion! Nice find on that GLI too! I should have picked up a GLI or something nice and done that instead of the '85 jetta I did. Every diesel Jetta I see for sale is always a worn out pile! There are some nice gas ones that are real survivors though.
I'm back around on here again as I scored volvo with a D24T... I should be sounding like my cummins here shortly! I was almost thinking of sticking some "C" badges on the front fenders just to mess with the local truck guys...
Just wanted to drop in and say good work.
Jason
thanks Jason!! yeah I'm on DTR, compD...pretty much all of them..lol
i am a hard core diesel freak...I love them!
WOOT WOOT
the postman left a note saying they tried to drop some thing off from "gaskets to go"!!!!
I will have my gaskets tomorrow MORNING!!!!!! :twisted:
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Well we are all interested to see how these work for you... I'm sure you'll be posting a couple pics of this new HG's???
Jason
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Well we are all interested to see how these work for you... I'm sure you'll be posting a couple pics of this new HG's???
Jason
forsure.... :D
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I'm sure you'll be happy to have her back on the road again. :)
I can't wait to start my diesel swap. This thread just makes me even more eager to do it.
-
got some more stuff done this week..
daisy chained my lighting for the gauges
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0576.jpg)
also built my drive pressure gauge tubing..
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0568.jpg)
I drilled out and through the old turbo support bolt hole...tapped it with some 1/8NPT and screwed in my compression fitting and my Custom coiled brake line tubing(by custom I mean I coiled it around my Mag light :lol: ) to cool the gases before they hit the poly tubing....I also made a soot filter(filled with brilo pad)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0567.jpg)
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I also got this little bundle of joy!:twisted: :twisted: :twisted: :twisted: :twisted:
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/MLSgasket.jpg)
opened it up... and found both theses little beauties...
2 notch
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0550.jpg)
3 notch
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0552.jpg)
out of the package...
it looks great!!! I am pretty impressed with the quality..
it did have some slightly rough edges around the #1 and #2 bore hole...but nothing to be worried about..
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0553.jpg)
hurried and took it outside to check it against the head...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0566.jpg)
PERFECT MATCH!!!!!!!(it looks a little off in the pic..but that cause I'm trying to hold it with one and and take a pic with my SLR camera)
:D
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0566.jpg)
note the steam pocket holes!! 8)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0564.jpg)
Put the new MLS on the block..marked the holes with a sharpy
laid out some painters tape and drilled the steam pocket holes.
the holes end up being pretty darn deep...at least 1/2"+
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0557.jpg)
Done..
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0558.jpg)
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on the block it looks just as pretty!..lol
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0559.jpg)
you can kinda see the rough edge in this pic.
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0560.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0561.jpg)
I slapped the head on TQ'ed it in steps and proper sequence to 80ftlbs..I will start and run it WITH NO COOLANT CAP to get it up to operating temp.then I will let it cool and do a re TQ@90ftlbs..
Drive pressure gauge installed...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0569.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0574.jpg)
I have ran it tonight...I'm waiting for it to fully cool and I will re torque it in the morning and then it's GO TIME....
:twisted:
finally!!!
I'm gonna be nice to it this time....no 20 psi rally runs:lol: ...least not till I get some time in the drivers seat...
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Very nice work... nothing like that first fire-up, is there??!!
Guess which part I like the most ???
Yup, the glow plug wiring !! 8)
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Very nice work... nothing like that first fire-up, is there??!!
Guess which part I like the most ???
Yup, the glow plug wiring !! 8)
LOL thanks Vince!!...I love the GP wiring aswell!! great idea!
yes it's a good feeling to have it running again..
I also got my new water temp gauge installed..IN THE TOP HOSE housing.....I was kinda disturbed when the fans did not kick on until about 220* :shock: ....I think I'm gonna order a cooler fan switch from GAP...
seems way to late to try and cool this baby down when the head coolant is at 220*???
I really don't like the VW cooling systems :( does not seem like the ideal set-up...
:roll:
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You and me both buddy! Hahahah
Perfect timing :P we have identical EGT sender mounts. Like i don't think they're more than 5 degrees out from each other there on the manifold hahahahha
Augh im so envious of that downpipe and probably done out IP.
What is the use of the manifold pressure?
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Good to hear its going back together. I agree on the VW cooling system i feel several VW engines would still be around if the cooling system would have been a little better. I plan to install a coolant temp gauge to see where it actually is during regular beatings.
The same with the drive pressure gauge. Do you have a list of all the parts you used for the drive pressure gauge?
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lots of headgaskets die in the diesel world from extreme cylinder pressures...when tuning a diesel with a BIG turbo you want to try and get as close to a 1.1 ratio of pressure between the turbo pressure and the exhaust pressure.....
so I installed a drive pressure gauge so I can "tune" my turbo to be least abusive on my new head gasket as possible.
I did the DP gauge so I can FULLY tune this beast...although I do need a wastegate to make the most of this set-up..but times are tight so the wastegate will be added later....
thanks gents...
I will add a list of my DP gauge parts soon as I get back...
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Well good thing your turbo has a waste gate built in huh???
Easy to tune as well.
Looking forward to some test rides once again. I dang near stopped by last night to freeze with ya for a min but, Wednesdays = Scouts so i had to boogie on through.
Sure is looking good Mark.
You driving it to work today?
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Well good thing your turbo has a waste gate built in huh???
Easy to tune as well.
Looking forward to some test rides once again. I dang near stopped by last night to freeze with ya for a min but, Wednesdays = Scouts so i had to boogie on through.
Sure is looking good Mark.
You driving it to work today?
thanks Dan...I blame you for all this money pit and diesel fun!! :lol:
I pretty much did not plan on using the stock gate...the stock gate does not have that much adjustable does it Dan???
if it does maybe I will tune it with that??
I dont work today..hope to drive it to work tomorrow tho...
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some guys are asking what parts I used to make my DP gauge..so here goes..
3' of 3/16" steel brake line..coiled around my "2 D mag light"
1 90* 1/8NPT to 3/16" compression fitting
1 male 1/8NPT to 3/16" compression fitting
the other two compression fittings came with my gauge..
I made the soot filter with some solid aluminum bar stock(homedepot) I drilled it out for some 1/8" npt..pretty simple really.
clear as mud??
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Thanks for the list. It looks like a good setup so thats why i asked i plan to make one similar to that.
I believe that several headgaskets have died from extreme cylinder pressures. But i'm talking about daily driven stock VWs that people just drive and it gets hot and ruins the head.
All in all can't wait to see how your HG works. Also am interested in how the hybrid turbo runs. Keep us posted.
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Well good thing your turbo has a waste gate built in huh???
Easy to tune as well.
Looking forward to some test rides once again. I dang near stopped by last night to freeze with ya for a min but, Wednesdays = Scouts so i had to boogie on through.
Sure is looking good Mark.
You driving it to work today?
thanks Dan...I blame you for all this money pit and diesel fun!! :lol:
I pretty much did not plan on using the stock gate...the stock gate does not have that much adjustable does it Dan???
if it does maybe I will tune it with that??
I don't work today..hope to drive it to work tomorrow tho...
I think you could use the OE WG. Just install an adjustable T fitting in between the manifold and WG so you can adjust when it opens.
When it's completely unhooked as your and mine are we don't even need to adjust that screw all the way as as we did. You can adjust that for along with the T fitting to get the WG to open when and how much.
Plus we can take one, cut it open for larger springs ect and just make a ring to reassemble the 2 half's once done.
WAY less than an external WG.
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I wonder what the ratio would be with no controlling it... the Drive pressure and boost pressure that is. ie. a set up like mine where you get as much boost as fuel you push through it with no BOV or waste gate.
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Fail!!!
Details when I'm not so efing pissed.....
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Fail? :(
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I'm coming over man!!
Be there in 45 min..
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Guess I should log on more often..
Ive been spending time doing the same swap. Down to the G60 v/c, same FMIC and its even a solid lifter 85 engine.
Cept mine is a 90 GLI and its BLACK.
I almost bought a haggard 89 Helios for $400 to do the swap into. The Vortex would have imploded.
Im going to send you a PM about those gaskets (ill need 2) when I hear that all is better.
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well I got it put togather last day before yesterday...I warmed it up and retqed it yeterday...took it for a ride..10psi was the most I pushed it..
came back home feeling great!!
look under the car and see red coolant dripping down...at the back of the engine! :(
grab my inspection mirror and start looking...the damn head gasket is seeping coolant on the back side of the head and block!!!! :cry: :evil: :cry: :evil: :cry: :evil:
so after punching a few holes in my garage walls!!!!(jk)
I started to take the car back apart to see why...after I got it apart I pretty much came to the conclusion that I did not get the gasket FULLY smashed...I clean the surfaces again..and this time I applied some permatex Aviation form-A-gasket sealer...and put it all back together.....head off, cleaned, inspected and reinstalled in about 2.5 hours!!! I'm getting good now! lol
I took the studs to 95ftlbs...I'm gonna warm it up and go to 105ftlbs
if this SOB does not seal now..well I dont know what I will do!!!!!!!!!
to be continued...........
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I'm coming over man!!
Be there in 45 min..
I also need to thank Dan for coming by and talking me down from the ledge!!!
I was at my wits end yesterday.......
thanks dan!! 8)
Mark
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Bummer. I'm intersted to hear about your results. The IDI is the _only_ engine I've ever rebuilt that I did not apply avaition peratex to all the gaskets, espeically the head.
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I know MLS has to have a REALLY smooth surface to mate up to...but I really thought my decked head and block surface would be fine???
I sure hope the extra TQ and sealer will work......
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Apparently, you need about 20 RA surface for the MLS to seal properly.
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Apparently, you need about 20 RA surface for the MLS to seal properly.
"cometic" says 50RA..
http://www.cometic.com/faq.aspx#q4
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well I just finished taking her for a nice burn around the block..
apparently 110ftlbs!!!! is what it takes to crush this MLS and I think the Aviation sealer help a ton too...
WOOT WOOOT!!
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OMG !!! 110 ft/lb !!! How close is that to shearing off the bolts / studs ?
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OMG !!! 110 ft/lb !!! How close is that to shearing off the bolts / studs ?
:twisted: :twisted: :twisted: :twisted: :twisted: :twisted:
I will tell you my secret formula soon.... :twisted:
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I'd have to go back over my TDI (mls headgasket) head bolts to compare, but that 110 is close to the 105-110 ft-lbs I used to get on the old fiber gaskets (after all the retorques), as noted earlier in this thread.
Good to hear you finally (hopefully) solved the problem.
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well here is what I did ..
1~aviation permatex sealer on both sides of the gasket..
2~torqued in proper sequence and steps
35ftlbs
50ftlbs
75ftlbs
95ftlbs
then I filled it with coolant and plugged in the block heater...
I knew I wanted to take the studs way past the ARP spec and I noticed that when I retorqued the studs after RUNNING the engine it has was most the molylube off and I was getting "popping" and "jerking" when I retorqued...so my thought this time was plug the block heater in let it warm the whole block over night..then come out and clamp the SOB down with 110ftlbs.....
as I did the retroqued I could tell the gasket had not fully crushed and I was getting nice and tight as I kept going 8)
I only had 1 stud "pop" on me witch made me feel like I was getting some good even clamping force from nicely lube stud threads..
as of right now I dont think I would go much past 110ftlbs....that was starting to really get tight..
I'm gonna take and run some more testing on it in the am...I had to work today so my time was limited..
I was beginning to think it was never gonna seal!..
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15PSI AND HOLDING STRONG!!
man it's running even better then before(weird but it ran nice even with a blown HG before)
I'm gonna drive it to work tonight...wish me luck...I don't get off till 1am..so it could be a long nigh. :lol:
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Good luck and happy boosting! :twisted:
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did you get off work yet? :D :D how much was this gasket?
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OMG !!! 110 ft/lb !!! How close is that to shearing off the bolts / studs ?
my raceWEAR stretch i mean 'studs' gave out at approx 90 ft/lbs. :roll: ARP FTW!
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did you get off work yet? :D :D how much was this gasket?
no still at work.. :(
1 and 2 notch gaskets are=$139.95
3 notch gaskets are=$149.95
then it's like $12 for shipping...
worth it from what I can tell...you just need to make sure to clamp the studs down nice and tight so the gaskets fully crush..
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OMG !!! 110 ft/lb !!! How close is that to shearing off the bolts / studs ?
my raceWEAR stretch i mean 'studs' gave out at approx 90 ft/lbs. :roll: ARP FTW!
so you had some bad issues with the beloved raceware???
I thought those are supposed to be "the best"
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Well, it has taken me the last 3 nights here and there to read through this thread, and I finally made it to page 20!!! Now I am setting here awaiting the news to see how it did on your trip to and fro work!!!
Keep up the great work and especially the posts with pics!
I have learned so much and cannot wait to tear down my 86 Golf Diesel and rebuild it with everything I learned here!
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Well, it has taken me the last 3 nights here and there to read through this thread, and I finally made it to page 20!!! Now I am setting here awaiting the news to see how it did on your trip to and fro work!!!
Keep up the great work and especially the posts with pics!
I have learned so much and cannot wait to tear down my 86 Golf Diesel and rebuild it with everything I learned here!
hey thanks alot man!! I still got LOTS of work to do...
I would say the MLS is a success!!!! I drove to and from my work last night with no engine issues at ALL..the worst part is my heater resistor pack is blown...and my blower motor is shot so it rattling and bouncing around!!
so hey I would say success if that all I can complain about!!
I took it up a nice big hill on my way home...18-19psi... holding strong..
:twisted:
I'm trying to keep the boost down under 20psi......
it's hard....boost= :D
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I took it up a nice big hill on my way home...18-19psi... holding strong..
:twisted:
I'm trying to keep the boost down under 20psi...... it's hard....boost= :D
congrats on the trip to work and back!
soooooo hard to keep boost under 20 lol
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I forgot to add...my ride to work is a pretty big drive...68 miles round trip..
nothing like Zukgod1's commute! but still a pretty good test run..
just installed my lower temp fan switch into the radiator..the engine is not really running hot..operating temp is about 195-205*...but for the summer time and AC on..I think I will want to give the fan a head start on the cool down
:wink:
I also took the control arms back off today....these dang audi TT bushing are not the perfect upgrade...someone really need to make a sleeve for the MK2bolt/TTbushing..there is just to much slop in these things for me to feel good about them.
I'm gonna make some sleeves today..hopefully that tightens then up..
did I tell you guys how excited I am?!?!?!?!?!? :lol:
WOOT WOOT :D
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Originally, the MK2 had a sleeve in the bushings. Sometimes, they rust to the inside of the old bushing, and you can't see them.
Did you install a new MK2 sleeve on the bushing when you installed the TT bushings?
I'm asking because, I have a GLI, and am thinking of rebuilding the a-arms with the TT bushings. I may pass on that idea, if I have to make a custom sleeve for the bolt/bushing.
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Originally, the MK2 had a sleeve in the bushings. Sometimes, they rust to the inside of the old bushing, and you can't see them.
Did you install a new MK2 sleeve on the bushing when you installed the TT bushings?
I'm asking because, I have a GLI, and am thinking of rebuilding the a-arms with the TT bushings. I may pass on that idea, if I have to make a custom sleeve for the bolt/bushing.
well on vortex I found some threads and most of them are saying just torque it down tighter..or add a washer so the sub frame can pinch the bushing in place....
to me that is unacceptable..
if it loosened up later and moved you would lose your alignment.
the stock MK2 sleeve does not fit with the TT bushing. If you want the bushing and the bolt to be 100% straight and aligned (like the stock MK2 bushing and sleeve do) then you need to build a sleeve of some sort to take up the slack in the bushing hole..
clear as mud?
I'm gonna take some pics....
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Incredible project, hope i can put that much work into mine !!! Really nice diesel !!! Keep up the good work ! :twisted:
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Dear 53 Willys,
nice to see, that you engine runs. I was very scarry, when i read, that you gasket (i get my on the same day) was leaking on the first start up. As i understood you right, everthink is fine now.
You have a 1.9 AAZ head or? If yes the compression ratio should be less than stock, how is you engine starts, do you feel a differend at start up or even until it is warm?
Best Regards
Clemens
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Dear 53 Willys,
nice to see, that you engine runs. I was very scarry, when i read, that you gasket (i get my on the same day) was leaking on the first start up. As i understood you right, everthink is fine now.
You have a 1.9 AAZ head or? If yes the compression ratio should be less than stock, how is you engine starts, do you feel a differend at start up or even until it is warm?
Best Regards
Clemens
yes everything is holding great now!!
my engine is a early 1.6td CY code...it's FULL mechanical..head and block. :twisted:
I am running the correct size headgasket for my application...so it starts GREAT!! :wink:
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some more update....I was not happy with my R32/TT control arm bushings...so I did this to fix them....
well after reading all the great reviews about the R32/TT bushing on the MK2's I figured I would try it since my stock bushings were gone....
I ordered all my control arm bushings from GAP...fast shipping just like always...
I get my parts go to install them and I realized when I am test fitting everything that the STOCK bushing bolt is WAAAAY to small for the stock R32/TT bushing...I tried to find some info on vortex about it but all I could find was threads saying that they don't need a sleeve and that you just need to tighten down the bolt more....
this is just plain stupid IMHO...the bolts fit TIGHT from the factory...and they are FAR FAR from tight with a R32/TT bushing.
so I call GAP and they tell me I'm the first person to have this "issue" I really surprised that this is such a talked up upgrade when it is not a BOLT IN UPGRADE..yes the sub frame might hold the arms in place if you go super tight..but that's not how this stuff should be!!
Basically I decided to build my own sleeves to make the bolt fit squarely and snug...without over torquing the bolt and just "hoping" it will not move and mess your alignment out.
here is the problem...
lots and lots of slop!! :thumbdown:
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0577-1.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0576-1.jpg)
so what I did was take a 5/8"X3.5" grade 8 bolt..I cut the smooth shoulder off...and drilled it out to fit my metric bushing mounting bolt(stock bolt)..after the hole is drilled in the 5/8" bolt...you need to drill out the R32/TT bushing to you can "press fit" the new sleeve into place.
I used a 39/64" drill bit for the press fit hole in the R32/TT bushing..
here is a shot of the 39/64" drill bit~NEW sleeve~ and a 5/8" bolt to show what the sleeve was made from..
you can also see that one sleeve is all ready installed..the other just needs to be pressed in.
My sleeves did not come out "perfectly straight and square"...but they are a nice tight fit and they will for sure hold better then with no sleeve.
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0581.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0579.jpg)
Stock R32/TT hole next to my drilled out and sleeved R32/TT
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0575-1.jpg)
new sleeves installed and no more sloppy bolt holes and clunking Arms... :thumbup: :cool:
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0582.jpg)
i'm happy with the results...and cant belive all you guys run this set-up without a sleeve!! :screwy:
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Those gauges are great. I may end up using them as well. What color do they light up?
the isspros I have light up green.....like stock..
need to clarify...I was under the impression my gauges light up green...but to my surprise they are just plain yellow lighting...I had some in my old doge and they were green...
I just wanted to correct this so people are not mad if the get this style isspro gauge and its not green.
what I will say is you can change the bulbs to a LED of your choice and they REALLY glow nice!!!
More on gauge lighting....next week.
word of the day...
coolant leak....but not from the headgasket...a hose or something..i'll find it.
8)
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Incredible project, hope i can put that much work into mine !!! Really nice diesel !!! Keep up the good work ! :twisted:
thanks Jetpo!!
I still kinda wish I had a 1.9.....next time..
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I sure am glad this car is moving now.
Those control arm bushing you made look really nice Mark, I suspect I'll go with stock bushings should I ever change them. I don't want to mess with making bushings for the new "Bushing-less" TT ones. Seems stupid to me. That should tell you the general intelligence level other "there" if ya know what I mean.
I need to come by for a ride next week, I'll text ya at some point to see if we can meet up.
Time for intakes now? Maybe I should wait till the VC comes back before I give you a hard time :lol:
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Dear 53Willys,
something new here? Is the car still running fine. Are you shedule to make a dyno run? Are you running high boost now or still keep it smooth?
Best Regards
Clemens
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Dear 53Willys,
something new here? Is the car still running fine. Are you shedule to make a dyno run? Are you running high boost now or still keep it smooth?
Best Regards
Clemens
well I have been driving lots...even tho I don't have it registered :oops:
it running VERY VERY strong...I'm hitting 20psi often..and all seems well 8)
I'm still trying to be easy on it so all this 20psi has been slowly building it to 20psi...no full throttle hard hitting boost yet...honestly I'm still kinda scared :lol: :oops: I dont want to take the head off again...
it runs super cool now too...I love this little car.
the k24/k26 turbo is a little laggy but I really like how it pulls once it does lite off....
I'm tiring to find a cheap k14 for some compounds... :twisted:
-
oh yeah... I plan to dyno it this spring..
it should do really well...i think...it runs so nice..better then I even expected.
-
How fast do you think it is with that turbo? Like it should be really, really fast. Dutzy ran 13's with a k26
The 24/26 hybrid turbo seems to be great.
Just for kicks I swapped on a full 24 so I could compare the spool up time between the 2 and to tell ya the truth I could not tell a difference at all so I re installed the 24/26 turbo.
The hybrid turbo gives me lower EGT's at cruising speeds.
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How fast do you think it is with that turbo? Like it should be really, really fast. Dutzy ran 13's with a k26
it for sure feels fast...but I have not drag raced enough to guess on a 1/4 mile time..
I will run it at the strip and dyno this spring....
-
:D
I just finished mine too!!! The t3 gives a nice surpise too. No insta-boost by any standard but once it's there its THERE. It'll go over 20psi noooo problem. I'm having ussues with blowing the rubber lines to and from the LDA out. Need hose clamps for them :roll:
Can't wait to insure mine :twisted:
I already have a mini ski trip for the day it's insured.
I'd LOVE to one day add a k12 to mine. What a sweet built.
The port/polished aaz head and polished tdi intake on mine completely transformed the engine. It's a fast revving (it will get the rpm up quick) super easy breathing throaty beast now. IT sounds so nice. I can't wait to show you all a video. I wanna see a video of yours!
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:D
I just finished mine too!!! The t3 gives a nice surpise too. No insta-boost by any standard but once it's there its THERE. It'll go over 20psi noooo problem. I'm having ussues with blowing the rubber lines to and from the LDA out. Need hose clamps for them :roll:
Can't wait to insure mine :twisted:
I already have a mini ski trip for the day it's insured.
I'd LOVE to one day add a k12 to mine. What a sweet built.
The port/polished aaz head and polished tdi intake on mine completely transformed the engine. It's a fast revving (it will get the rpm up quick) super easy breathing throaty beast now. IT sounds so nice. I can't wait to show you all a video. I wanna see a video of yours!
right on Eddy...and thanks! 8)
I too have noticed a very free revving engine and nice spool times, and the EGT's seem really manageable..(my max is 1200* while railing on it up some hills)**Note** I am at 4500-5000 ft elevation so I do fight thin air and increased spool times a little more then you sea level guys..
But I really must say this little car is a blast!! it's really a mean running SOB!! it seems to really sound and enjoy the higher rpm ranges...it really sings..all the TIME and CASH is paying off now :twisted:
I will make a vid with some 0-60 runs and we can try to time it with the video cameras timer.. :D it's FAST and this clutch LOVES fast firm shifts...it's sweet.
one thing I may change is the hydro mounts....although they are nice for keeping idle vibs down...they seem to flex to much IMHO...My IC tubing is bouncing around are high power shifts.....
I also need to get my radio hooked up....I like the sound of the diesel....but I need some tunes too :lol:
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we nee a video and picture area so we can all whore out our cars! 8) I wanna see spool up time in video with shots of the boost guage.
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we nee a video and picture area so we can all whore out our cars! 8) I wanna see spool up time in video with shots of the boost guage.
I wish I would have done that on my first build.
you should have seen my friends face when that gauge hit 40 psi! :shock:
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40?!?!?!?!!
I was going to say i'd love to show a video of my gauge going dead when it blows the rubber line off hahaha
I'd much rather show a vid of my tach working. I've been putting some time and thought into it lately with the help of Vince.
the spool time of my t3 is actually so comical.
ok go! bbrrrrrrrrRRRRRRR wwwwwwwwooooooo (10 psi) WOOOOOOO( 20!) WWWWWWWOOOOOOOOO!!!!! (25+!!!) WOOOOOOSSHSHSHSHSHS!!!!! *shift* 8) Wwwwwwwwwwwwwwwwoooooooooooooo(20) and so on. :roll:
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UPDATE=K24/K26 is TOAST!!!
well tonight I blew my turbo up!! pushed the compressor wheel right into the compressor housing :evil:
sighhhhh...I was just thinking today how well this car has been running too!! oh well...new turbo/s for me!!!
so the next question is....
ball bearing turbo??...VNT Turbo?? or compounds?(k14 over a k26) :twisted:
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Dang ! did it over speed?Id go vnt.
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if you can, VNT, if you can't compound :twisted:
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Any ideas as to why it grenaded? that sounds bad, I would like to see another VNT...mostly so the mechanical linkage bugs are all worked out when I want to do it :D.
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Mark let me know as soon as you know what you need as to parts.
If the bearings and shaft are ok I have another k26 compressor wheel I can drop off.
I also have a few bearings that are good.
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hey thanks for your help Dan!! (as always!!! you have been a big help!)
I don't know why it went out???
maybe I did something wrong when I rebuilt it?? although I don't know what it could be since I did it just like the instructions from KKK said...
it went south om my way to work..(35miles from home) when I took the air filter off to check the shaft the shaft nut was about 5 turns from falling off and getting sucked into the compressor!!!
after a bunch of texting between Zukgod1 and I I decided to bypass the turbo and run it in NA mode....I left the oil line hooked up just in case the turbo was not completely done for..I wanted it to have some lube so I left the lines on..
by the time I babied the car home for 35 miles to my house I raised the hood to find the oil seal went on my way home and proceeded to pump oil into the compressor housing!!
good thing I bypassed my turbo!!! and runaway engine at 1:30 in the morning is NOT COOL!! lol
I would like to find a VNT-20..but what car did they come on?? where can I get a VNT-20?? I need it right now too!! other wise I'm gonna call industrial injection and get a turbo from them...or better yet get me a turbonitics Ball bearing turbo
:twisted:
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I'd try a BB turbo if i had the cash.
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If you could get a BB turbo with the Merc specs I bet you would be very happy with it.
Would have a larger compressor but it would be able to spool like a k14!!
I have a contact @ High-Tech as well so let me know what you decide to do maybe we can get a T3 built with BB journals for a good price.
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I second that!
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If you could get a BB turbo with the Merc specs I bet you would be very happy with it.
Would have a larger compressor but it would be able to spool like a k14!!
I have a contact @ High-Tech as well so let me know what you decide to do maybe we can get a T3 built with BB journals for a good price.
call him!!! I need to get this running soon!!! I sold my truck this week so I don't have a backup car/truck right now!!
get me a price please?!?!
what is the "name" of the k26 mounting foot style??
and what is the "name" of the stock 1.6TD manifold foot??
t-3 mounts???
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I think it's just a Trapezoid flange. Your going to have to either change your manifold to get the T3 foot or make an adapter to mount the T3 to your manifold.
The later would be the easiest I bet as you already have the Trapezoid flange made as your spacer now.
I just dropped my guy a text and he is still @ HT.
I'll report back VIA text as to what if anything he can do for ya.
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I just talked to Turbonetics...I'm gonna send them my build sheet and they are gonna quote me on a DIESEL SPEC ceramic ball bearing turbo!
probably gonna be to expensive tho????
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I bet $$$$ Cha Ching!!!
What are you looking for as to the specs?
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I bet $$$$ Cha Ching!!!
What are you looking for as to the specs?
big and spoolable??? lol
I really like the K24/26..but the gasser RPM range is kinda ***ty...I want a turbo with a better turbo map
I would rather NOT fab up compounds for it right now even tho that would be my favored set-up..
I want the K26 turbo with a diesel map?!?!?!?
what about this manifold for a t-3 mount??
would this work??
http://cgi.ebay.com/ebaymotors/VW-Golf-Jetta-2-0L-Turbo-Exhaust-Manifold-T3-T4-Flange_W0QQcmdZViewItemQQ_trkparmsZ72Q3a1205Q7c66Q3a2Q7c65Q3a12Q7c39Q3a1Q7c240Q3a1318Q7c301Q3a0Q7c293Q3a1Q7c294Q3a50QQ_trksidZp3286Q2ec0Q2em14QQhashZitem390031541126QQitemZ390031541126QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories
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Yes that manifold will be fine.
Send me a copy of the build sheet so I can forward to my guy in SLC.
He said he doesn't have the ability to build a BB turbo there but recommended a Garret gt2860 as a off the shelf BB turbo.
Once you tell me what specs your looking for I will have him get us a price on a Wet Journal turbo. so you have options.
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Here is a turbo I was looking at for specs.
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MEWAX:IT&item=180212515198
It looks like a Chinese turbo but the price is good and the specs are that of a T3 off a Merc.
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the build sheet is in PDF and it's the kind you can "add to" so I will show my build sheet here and you can copy and paste it..
this is the same questions Turbonetics asks you to fill out when you get a custom turbo built from them...
VEHICLE DETAILS
Make: Volkswagen
Model: Jetta
year: 1991
transmission: Manual
trans type: ASF
POWER INFO
Stock HP: 58hp
Max HP desired: 200hp
Max RPM: 5,500
Max Boost: 25-30
Intercooled: Yes
intended use: STREET and TRACK
If "street" what is most important? LOW END/MIDRANGE/TOP END HP:mid range
If "street" is the engine built? (rods,pistons,etc): stock bottom end~MLS head gasket with ARP head studs~port and polished head~gaskets matched intake and exhaust manifolds~
ENGINE DETAILS
Type: Volkswagen CY diesel
Number of Cyl: 4
Number of valves: 8
Displacement: 1.6 liters/1588cc
Compression Ratio: 23.1
Fuel used: Diesel
is the engine carbureted: No
whats your normal altitude: 4,562 feet
other important info or details:
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Let me know what you get for a reply.
I think they are going to reply with a .48 AR on the exhaust side but I'm not sure on the intake side.
my guy @ HT can build one (not BB) as well as soon as we know the details so we can compair.
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Here is a turbo I was looking at for specs.
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MEWAX:IT&item=180212515198
It looks like a Chinese turbo but the price is good and the specs are that of a T3 off a Merc.
I'm kinda scared of the china turbos!!!
was it not ARB who bought a china turbo and it was balanced by just grinding the HELL out of the turbo nut??
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Yes that manifold will be fine.
Send me a copy of the build sheet so I can forward to my guy in SLC.
He said he doesn't have the ability to build a BB turbo there but recommended a Garret gt2860 as a off the shelf BB turbo.
Once you tell me what specs your looking for I will have him get us a price on a Wet Journal turbo. so you have options.
did your buddy tell you how much that Garret you listed above would cost??
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Sorry for my ignorance, what do the different stages mean? stage 1,2,3,4,5.
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Yes that manifold will be fine.
Send me a copy of the build sheet so I can forward to my guy in SLC.
He said he doesn't have the ability to build a BB turbo there but recommended a Garret gt2860 as a off the shelf BB turbo.
Once you tell me what specs your looking for I will have him get us a price on a Wet Journal turbo. so you have options.
did your buddy tell you how much that Garret you listed above would cost??
Nope no price.
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Here is a turbo I was looking at for specs.
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&ssPageName=STRK:MEWAX:IT&item=180212515198
It looks like a Chinese turbo but the price is good and the specs are that of a T3 off a Merc.
I'm kinda scared of the china turbos!!!
was it not ARB who bought a china turbo and it was balanced by just grinding the HELL out of the turbo nut??
It may have been but it may work just fine. Hard to say really.
I'm guessing there are allot of them out there being used now.
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Sorry for my ignorance, what do the different stages mean? stage 1,2,3,4,5.
basically the higher the stage the more air it can move..or
the higher the number the bigger the compressor and turbine wheels are..
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Sorry for my ignorance, what do the different stages mean? stage 1,2,3,4,5.
basically the higher the stage the more air it can move..or
the higher the number the bigger the compressor and turbine wheels are..
Also the slower it will spool :?
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Yes that manifold will be fine.
Send me a copy of the build sheet so I can forward to my guy in SLC.
He said he doesn't have the ability to build a BB turbo there but recommended a Garret gt2860 as a off the shelf BB turbo.
Once you tell me what specs your looking for I will have him get us a price on a Wet Journal turbo. so you have options.
did your buddy tell you how much that Garret you listed above would cost??
Nope no price.
I found some prices...and that GT turbos is a little big from what I can tell?? saying it supports 250+hp
I really want a good spooling turbo that is good for 250hp MAX!!
and I want it to have a good diesel map not a gasser map
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I think finding a Garret T3 that was originally on the TD will be your best bet.
I think noSurender had one in the classifieds.
Being a T3 Garrett parts will be available and it should be durable as well.
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I think finding a Garret T3 that was originally on the TD will be your best bet.
I think noSurender had one in the classifieds.
Being a T3 Garrett parts will be available and it should be durable as well.
I'm not buying any used turbos....my wife gave me the ok to get a "good turbo" so I think a turbonetics ceramic ball bearing turbo with external wastegate may be in the works :twisted:
if not I will get a off the shelf journal bearing turbo here locally for around $400
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oooo I want this manifold!!!
droool
http://www.kineticmotorsport.com/products/KINETIC_MOTORSPORT_VW_2L_8V_TURBO_MANIFOLD-467-93.html
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A guy on saablink purposely bought the cheapest t3/t4 he could find on ebay for $160 or so, to see how it would hold up, and apparently it's doing fine. :?
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What do you guys think of these two set-ups...
Ebay turbo manifold
http://cgi.ebay.com/ebaymotors/VW-Golf-Jetta-2-0L-Turbo-Exhaust-Manifold-T3-T4-Flange_W0QQcmdZViewItemQQ_trkparmsZ72Q3a1205Q7c66Q3a2Q7c65Q3a12Q7c39Q3a1Q7c240Q3a1318Q7c301Q3a0Q7c293Q3a1Q7c294Q3a50QQ_trksidZp3286Q2ec0Q2em14QQhashZitem200311007940QQitemZ200311007940QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories
And a Engineered Diesel ED wastegate and wastgate adapter.
http://engineereddiesel.com/wastegates
I'm worried that the ED wastegate setup will be to long and bulky for my engine bay??????????
so I was kinda thinking a set up like this would be better?? but more expensive...
http://www.kineticmotorsport.com/products/KINETIC_MOTORSPORT_VW_2L_8V_TURBO_MANIFOLD-467-93.html
and then I would need to find a 38mm wastegate...but I don't really know of any good diesel spec(if it matters even) wastgates??
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what do you want from the external wastegate?
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what do you want from the external wastegate?
high quality boost and drive pressure control....
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E bay manifold for sure.
Couldn't you machine an opening in it at work? If you could machine an opening then you could make a flange and mount the wastegate anywhere you wanted.
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thats an odd valve cover all of mine have the oil fill on the normal passenger side where yours is opposite! and i have 3 of them!
wher you find that one at?
other wise looks good!
keep the pics. coming!
Duane
yeah I dont know whats up with that cover?? I bought it from a guy on Vortex... the ad had no pics...anyway I am glad it has the oil filler on the drivers side cause my intercooler piping would cover the oil fill cap if it did not come on the drivers side.......some one said it was a G40 polo cover??? but I have no clue??? :oops:
thanks for the kind words 8)
If this isnt known Ive found where the VC is from. Its from a UK Mk3 8v GTI. Found a limey on the Vortex with one on his car and I asked.
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If your up Mark I have a theroy on your blown turbo.
Drop me a text.
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well turbonetics finally gave me my quote...they want $1,049.00 for the ceramic ball bearing turbo that will support 200hp..but still be usable in the lower RPM range...then I would still have to get a T3 exhaust manifold and a external wastegate...
so here is the break down
turbo=$1,049.00
manifold=$110.00
WG=$325.00
1,484.00 :x
so what are my options?? this would be a absolute KILLER set-up...but damn it's spendy!!
I'm real temped to get a journal bearing turbo..but I just can not seem to find one I want with good specs....I kinda want to try a K14..but they are expensive to buy..even used and I'm worried it is to small for my 170+hp goal?
I want the power...but I want usable power too.
VNT seems like waaaaaay to much hassle I would almost rather buy the high end turbo vs VNT...and I cant even locate a VNT17 or 20 anyways!
suggestions?
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thats an odd valve cover all of mine have the oil fill on the normal passenger side where yours is opposite! and i have 3 of them!
wher you find that one at?
other wise looks good!
keep the pics. coming!
Duane
yeah I dont know whats up with that cover?? I bought it from a guy on Vortex... the ad had no pics...anyway I am glad it has the oil filler on the drivers side cause my intercooler piping would cover the oil fill cap if it did not come on the drivers side.......some one said it was a G40 polo cover??? but I have no clue??? :oops:
thanks for the kind words 8)
If this isnt known Ive found where the VC is from. Its from a UK Mk3 8v GTI. Found a limey on the Vortex with one on his car and I asked.
Since nobody else knows what that valve cover came off of, allow the n00b. :lol:
Yours:
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0433.jpg)
Euro Spec Golf 3 GTI 2.0 8v. Engine code AGG. (What Europe got instead of the ABA.)
(http://www.volkswagenspares.com/UserFiles/Image/golf%202l%20gti%20under%20bonnet%20(Custom)%20(2).jpg)
Beat ya to it..... :wink:
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well turbonetics finally gave me my quote...they want $1,049.00 for the ceramic ball bearing turbo that will support 200hp..but still be usable in the lower RPM range...then I would still have to get a T3 exhaust manifold and a external wastegate...
so here is the break down
turbo=$1,049.00
manifold=$110.00
WG=$325.00
1,484.00 :x
ok, so instead of working the guts out of a single turbo on these motors.. and either having good spool off the line and none up top, or have no spool off the line but have it pull like a mother after about 3500.. why not take the best of both worlds? have a smaller turbo.. like a VNT 17, 20 or something for your first turbo, and have somethin quite a bit bigger for the 2nd turbo. im really fond of the compound turbo idea. 3/4 ton diesels sure like compounds. and if you had big enough turbos, and WG's set up good, drive pressure shouldnt be an issue should it? and pretty much im talking fabricate every aspect of this setup.. a custom fabbed manifold would probably be the best bet im thinking.. i havent seen a manifold for under 700 bucks that i thought would be any good at making power and keeping restriction down. i mean, maybe this is just a pipe dream of mine.. but popping the hood on my rabbit and seeing a turbo beside the engine would be cool. then look a little closer.. "holy crap, that thing has 2 turbos!" :twisted:
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well turbonetics finally gave me my quote...they want $1,049.00 for the ceramic ball bearing turbo that will support 200hp..but still be usable in the lower RPM range...then I would still have to get a T3 exhaust manifold and a external wastegate...
so here is the break down
turbo=$1,049.00
manifold=$110.00
WG=$325.00
1,484.00 :x
ok, so instead of working the guts out of a single turbo on these motors.. and either having good spool off the line and none up top, or have no spool off the line but have it pull like a mother after about 3500.. why not take the best of both worlds? have a smaller turbo.. like a VNT 17, 20 or something for your first turbo, and have somethin quite a bit bigger for the 2nd turbo. im really fond of the compound turbo idea. 3/4 ton diesels sure like compounds. and if you had big enough turbos, and WG's set up good, drive pressure shouldnt be an issue should it? and pretty much im talking fabricate every aspect of this setup.. a custom fabbed manifold would probably be the best bet im thinking.. i havent seen a manifold for under 700 bucks that i thought would be any good at making power and keeping restriction down. i mean, maybe this is just a pipe dream of mine.. but popping the hood on my rabbit and seeing a turbo beside the engine would be cool. then look a little closer.. "holy crap, that thing has 2 turbos!" :twisted:
hey man I am with you fully!! on the compounds...the ONE problem with compounds is they run lot's higher boost then a single...and that higher boost is gonna be murder on the head gasket!
I have been saying I want compounds from the get go!
but now that the headgasket is so hard to keep clamped down it worries me to run compounded turbos....
Shoot I could do compounds REALLY cheaply at this point...
I would just use my K26(with fresh rebuild) and snag one of the K14's in the classifieds....I just worry about the high boost that would come with this set-up..?
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well, how much boost are we talking here? think we could build 40 or 50 psi? maybe more? cause i had a stock 1.5 with just a turbo on it, and it would hit 25psi and stay there all day. that was with a fiber gasket and stock head bolts. and the messed up thing.. the block failed before the head gasket did. im pretty sure the head gasket blew cause the block cracked, as i just cant see it happening the other way around. but i wont do a compound setup until im fairly certain i can get a bottom end to hold it. i wanna take a 1.6 TD block and put 1.5 internals in it. then cap it off with an AAZ head and metal gasket with ARP studs.
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rebuilt k14 turbo=$450-$500
rebuilt k26 turbo=$350+new compressor wheel=$450??? give or take?
ED 40mm External WG=$325
$1,275
this is bare bones estimate though...just like the one above.
I would still spend maybe another $200 on miscellaneous parts fittings etc??
I guess twins would not be that cheap at this point after all...
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well, how much boost are we talking here? think we could build 40 or 50 psi? maybe more? cause i had a stock 1.5 with just a turbo on it, and it would hit 25psi and stay there all day. that was with a fiber gasket and stock head bolts. and the messed up thing.. the block failed before the head gasket did. im pretty sure the head gasket blew cause the block cracked, as i just cant see it happening the other way around. but i wont do a compound setup until im fairly certain i can get a bottom end to hold it. i wanna take a 1.6 TD block and put 1.5 internals in it. then cap it off with an AAZ head and metal gasket with ARP studs.
i dont think the aluminum head can hold 40-50psi of boost...just ask andy2..he could not keep his head clamped with firerings and a copper gasket!
from what I have seen and read anything over 30psi is SUPER risky...?
you also bring up a good point on the bottom end...yes our bottom ends are pretty stout..but compounds make boost at really low rpm's so bent rods are more likely on a compounded set up too?
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the VNT on my car builds boost super low. not huge boost, but its boost none the less. i can do an easy shift from first to second, roll on the throttle and start burning the tires. yesterday i was out driving around. and theres a hill by my house thats pretty steep, steep enough that i have to shift down in everything else that i own to climb it. i was going about 75 at the bottom and held her wide.. i was doing over 100 at the top and it was still gaining speed. if my turbo wasnt worn the f*ck out, it would probably boost even sooner. and bent rods dont really worry me that much. im not gonna run nitrous or propane. and im pretty sure somethings gonna give in the top end before we start seeing rods bend. those little bastards are some strong rods. and the crank, pfft. there bullet proof. the engine in my car now, i pulled it out and it had a bent rod. like really bent. looked more like a "C" than a rod. pretty much shattered the piston too. i was amazed how much destruction there was. took and honed the cylinders, got a used piston and rod from my grandpa, re ringed the whole setup, and threw it back together with the head off my old motor.
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sigh.....to many options!!! :?
I dont know what to do?!?!?
you kinda got me wanting compounds...but damn thats some big time fabing...and I just got this car rolling..be it not for long..lol
I could fab the twins my self..even do a exhaust manifold myself.
I guess I'm just being lazy...and kinda bitter at KKK turbos since my K26 took a dump..(my own fault I should have hooked the WG up :oops: )
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well, since im in the situation im in now (no drivers lisence) i really have nothing but time. my car doesnt have to run every day. and honestly.. i could mock it up on my gasser parts rabbit. a tubular manifold with a real collector would be the cats meow. and i heard a pretty crazy idea that sounded crazy enough to make sense. the idea was to put an expansion chamber (something like you would see on a 2 cycle motorbike) after there turbo. i read somewhere that it straightens out the turbulent gasses from the turbo and makes them flow better.
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my wife has given me the ok to pull the trigger on the BB unit...the more I read the spec sheet the more I think I may try this BB unit.....it's perfect diesel match...nobody but a select few (like KKK) make diesel spec turbos off the shelf and the few that I am finding are almost the same price as my custom unit....and still non BB......
my mouse finger is getting itchy!! :lol:
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that kinda turbo is it based from? or is it a completely custom job? i want either a set of compounds or one really good turbo for my next build.
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that kinda turbo is it based from? or is it a completely custom job? i want either a set of compounds or one really good turbo for my next build.
they suggested a custom T3 bb turbo
T3 45 Trim F1-54 .48 A/R
thats the specs on the turbo..dont know what it all means tho??
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53 Willys, you got PM! :)
About boost, my friend Aki ran 41 PSI on his AAZ twin charged engine, and a stock three-layer head gasket held up very nicely.
He did mention something about head studs and the right torque though...
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A K14 and K26 would make a nice compound pair. You don't have to run extreme pressure to get a compound systems benefits. Could run 15psi.
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i wanna run about 20 - 25 psi and have enough fuel to go with it. but is a VNT 17 any good for use as a small turbo in a compound setup?
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all right at this point I think i'm gonna go with the BB turbo..
I really dont want to mess with compounds right now :( and I like the idea of getting a brand new turbo built to my specs VS a off the shelf gasser turbo...or a KKK series turbos...I know lots of guys like the KKK's but mine blew up and Zukgod1 blew up 2 so far...they dont seem to hold together very well IMHO..but some of the blown turbos could have been self inflicted damage?
maybe in a year or so I can upgrade my BB unit and put a k14 on top of it or something...but for now I am conforming to the classic big single turbo..but this time it will spool LOTS sooner...and have a WAAAAY more usable range compared to my hybrid K26
:lol:
thanks for the help guys....
if anybody wants to try and talk me in a different route lets here it!!!
I'm not ordering my turbo and external wastegate until Monday....
so if you got something to say do it now before I order up!!
i'm open to suggestions!! 8)
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i actually wanna see how it works for you. cause i know that i need some sort of different turbo. i like that mine spools instantly, but im pretty sure its restrictive. i dont know how it couldnt be, the hole in the exhaust housing is like 1.45 inches. and that doesnt seem like enough flow.
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Compound turbo's on a diesel are far superior to a single. The torgue curve is generally a flat line. Singles don't compare. And what's the diff from gas to diesel turbo? A turbo has no idea what motor it's on.
I would sell the VNT and get standard turbos. For a 1.6, a GT12 for the high pressuer and a GT15 for the low pressure would give you up to 250hp.
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250 horses would be sweet.. no question. but im sure im never gonna build that kinda power with my IDI. 1.5's are probably pretty limited on the power numbers they run? and i know they dont build near the torque the 1.6/1.9's do, but i like the top end power. eventually i wanna throw together a 1.5/MF/AAZ engine. MF turbo block, 1.5 rotating assy, AAZ head w/ studs and a metal gasket. and probably some extensive porting.
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I have a 1.5 in my Samurai, I like how it revs. I have a little KO3 going on it next week. Then I going to compound that with a S1B Schwitzer when time allows.
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Compound turbo's on a diesel are far superior to a single. The torgue curve is generally a flat line. Singles don't compare. And what's the diff from gas to diesel turbo? A turbo has no idea what motor it's on.
I would sell the VNT and get standard turbos. For a 1.6, a GT12 for the high pressuer and a GT15 for the low pressure would give you up to 250hp.
You are right 100% that compound turbos are king on diesels...but they still make lots of low end boost..and I would have to/want to build them with a K14 and a K26..but when I look at spending the same money or dang close for the two KKK turbos to rebuilt..then materials to build a manifold and drains and all the other details for compounds I loose interest..I have been working on his car for 6 months now...I ready to get some drive time before I tear it back down.
plus this is a good way to get a real good big bottom turbo..then maybe stack a K14 on top of it in a year or so.
the gasser turbos are set-up to build boost at MUCH MUCH higher RPM's vs a Diesel speced turbo..
you dont need to convince me that compounded turbos kick ass on diesel......I know they do and will walk all over a single turbo..
I'm more thinking custom compounds...dual BB as my next upgrade :twisted: :twisted: :twisted: and getting this BB now is a good start
two BB compounded turbos and a ED external wastegate would be A SMOKING HOT SET UP!!! :twisted:
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Manifold and drains are easy. Are you saying you're too lazy and want to drive your project instead of work on it...? :lol:
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Manifold and drains are easy. Are you saying you're too lazy and want to drive your project instead of work on it...? :lol:
YES.... :lol:
I need at least 6 months of enjoyment before I tear back into it!! :P
they it will be another $1500 for a BB top turbo! :twisted: then will you be happy? :lol: can you give me 6 month???
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Compound turbo's on a diesel are far superior to a single. The torgue curve is generally a flat line. Singles don't compare. And what's the diff from gas to diesel turbo? A turbo has no idea what motor it's on.
I would sell the VNT and get standard turbos. For a 1.6, a GT12 for the high pressuer and a GT15 for the low pressure would give you up to 250hp.
i would wager that a VNT could compete with compound turbo's. unless of course the compounds were VNT... :lol:
the reason being is that the exhaust gases are actually directed to the turbine wheel by the variable vanes. ball bearing VNT would be insane!!
and as far as superiority vs single, of the same type, yes. BUT reliable? not quite so. you should really talk to andy2 on the problems he faced when going this route. it isn't as easy as plumbing everything up and it works perfectly... one problem in particular is the oil pressure loss.
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Compound VNT's would be a great project, would like to see that as well. I have a 1.5 with a 1.6 hydraulic oil pump, hoping this will take care of oil pressure issues I may have. A turbo doesn't need a ton of oil, you can restrict it at the turbo.
I haven't ran compounds on a VW, however on bigger setups like a 12 valve Cummins, compounds have proved quite relliable.
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YES.... :lol:
I need at least 6 months of enjoyment before I tear back into it!! :P
they it will be another $1500 for a BB top turbo! :twisted: then will you be happy? :lol: can you give me 6 month???
I'll give you 6 months, but after that, I'm gonna park my 1.5 compound turbo Samurai on the top of your car till it's done.... strictly for motivation of course....
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ok I bit the hardcore bullet and bought the Turbonetics Ceramic BB turbo and Engineered diesel External wastegate and t3 exhaust manifold.......
Here we go again!! :twisted:
part should be coming in this week 8)
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Holly hell man!!!
For some reason I feel like I should come by and beg for forgiveness from your wife!!!!
I'm really looking forward to you getting this turbo..
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Keep us posted and post up lost of pics!!
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That sounds spendy....
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Details! WHat model, turbo map?
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Details! WHat model, turbo map?
x2! I still need a new turbo for my build... If you don't mind me asking, what did it cost you? :twisted:
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I will get the map and try to post it or scan it....but really I did not look at the map...I had the turbonetics engineers spec this turbo to MY CARS specs and my power goals...so there may still be some more lag then some of you like since this is a about a 200hp(max) set-up..
on the flow sheet they did give it shows this turbo as 200hp@30psi 8)
MSRP on the custom turbo is $1398.00 :shock: but I'm a turbonetics dealer so I will get mine for a considerable amount less...but this is STILL a REALLY spendy set-up..the external gate was $460 with all the parts and flanges :shock: then another $110 for a ebay VW turbo manifold for a T-3.
it's gonna be SICK!!!! :twisted: :twisted: :twisted:
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Holly hell man!!!
For some reason I feel like I should come by and beg for forgiveness from your wife!!!!
I'm really looking forward to you getting this turbo..
haha yeah Dan it's all your fault!!!
:D
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Holly hell man!!!
For some reason I feel like I should come by and beg for forgiveness from your wife!!!!
I'm really looking forward to you getting this turbo..
haha yeah Dan it's all your fault!!!
:D
Ouch!
Dan hides in corner covering his face. :oops:
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Holly hell man!!!
For some reason I feel like I should come by and beg for forgiveness from your wife!!!!
I'm really looking forward to you getting this turbo..
haha yeah Dan it's all your fault!!!
:D
Ouch!
Dan hides in corner covering his face. :oops:
haah it's not all your fault dan....I already had the project sickness...so it would have happened either way..lol
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Stand by for turbo porn!!!! my BB turbonetics turbo came in yesterday....and it's just plain SEXY!!! :twisted:
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show us the money shot!
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HURRY UP ALREADY!!!!
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Oh WOW !!! Still waiting!!!
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Isnt 3 hrs enough time to post a pic?
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sorry the pics are uploading now!! 8)
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Isnt 3 hrs enough time to post a pic?
If you can go 3 hours for the money shot you can make loooooots of money in another line of work :lol:
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MONEY SHOT!!!
:shock: :lol: :twisted:
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0627.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0628.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0622.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0623.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0624.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0625.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0626.jpg)
I will get some side by side pics with it next to my K26.....still waiting for my wastegate......
Oh yeah I will have my down pipe up for sale soon if anybody needs a 3" down pipe that will fit KKK turbos...
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I was to flustered to actually type a reply for a bit there.....
Everyone inmy office is looking at me like there is something wrong..
DAYUM! that's sexy!!
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i can't wait to hear how this thing turns out.
just for clarification, a ball bearing turbo is oiled by the engine oil correct? i would assume that a better way to run these would be to have a sealed ball bearing and simply oil cool the turbo... i'd use a moly lube for the ball bearings 8)
looking good man! :D
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Yes they are still lubed by pressurized engine oil. They require less flow as well.
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That thing looks HUGE!!! :shock: Now go bolt it on and report back. :twisted:
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DROOL.
That must have cost 10x my turbo's price :oops:
Congrats! You'll smoke nigh-on everybody with that motha!
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If your running an external wastegate why does the turbine housing have a wastegate port? Looks good though can't wait to hear how it does.
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thanks guys...I'm super stoked about this new set-up.
yes this turbo is lubed by engine oil right of the filter flange just like the stock turbo....I thought ALL the BB turbos were coolant cooled aswell as oil cooled but not the Turbonetics.
it not as big as you all my think....pretty sure it's LOTS smaller then my K26 but I have not had them side by side yet....I still need to pull my K26 off the dub...I have been mad about all this so I just let it sit for a few weeks while all the parts show up...and it has given me a chance to get some other odd projects done.
turbo J it was not as much as you would think...when I was comparing it to turbos like yours they where pretty much the same price...maybe it's cause I'm in the USA??? but small turbos set-up for diesels are not easy to find or source....and prices suck when you do find them...most places want a core too and I had no core for the style turbo I wanted/needed.
the 5 bolt turbine housing can be set-up with a internal WG or external...this is the ONLY way I could get the set-up I wanted..but it's no big deal to just block the internal WG hole with a non-internal wastegate cover...
soon as my other parts show up I will mock it all up on zukgod1's spare head he let me barrow...i' m also building a PP style intake while I'm in here...
STAY TUNED :twisted: :twisted:
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You have PM re: HG!
Thanks!
-Brad
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PM about the Down pipe already :D
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first off I need to say "theman53" has first dibs on the DP :lol:
the mock up begins....I'm also building a PP style intake..I'm sure it wont be as pretty as Daves...but I have only tig welded aluminum a few times....who cares long as it get the job done better then the OEM intake. 8)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/IMG_0098.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/IMG_0097.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/IMG_0096.jpg)
wow Iphone sucks at pics..... :x
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yea seems like it has lighting issues.
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wow you guys put 20X more money, time and effort into your VW's than i do... holy CRAP.
What a nice looking little turbo D. my intake "enhancement" was just polishing the inside of an ALH intake hahhahaha!!!!
what an exhaust manifold too... where is that from again?
PS. weld that wastegate shut!!!
like me :lol:
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wow you guys put 20X more money, time and effort into your VW's than i do... holy CRAP.
What a nice looking little turbo D. my intake "enhancement" was just polishing the inside of an ALH intake hahhahaha!!!!
what an exhaust manifold too... where is that from again?
PS. weld that wastegate shut!!!
like me :lol:
haha thanks Ed.....
when you sell your brand new truck to get your wife a nice grand Cherokee with a 3.0 CR Mercedes Benz diesel....suddenly buying a good turbo for my $1400 car seems like a sweet deal..lol....when the wife's happy...I'm happy
I'm defiantly not gonna run this with no wastegate....my other turbo only lasted 900 miles like that....maybe the T3 can handle it?...but my K turbo defiantly could not...and neither could Zukgod1's 2 kkk turbos that he blew....
wastegate is your friend!!!! :wink: :D
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.when the wife's happy...I'm happy
Happy wife, Happy life 8)
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well I got my wastegate and some other parts....here is the beginning mock-up....right now I'm worried that the turbo will not fit with this manifold...I'm afraid it's gonna stick right into the rain tray...?
I will get some no iphone pic later...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/turbopic3.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/turbopics4.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/turbopics5.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/turbopics.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/turbopics2.jpg)
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Perhaps a different exhaust manifold. I Nnoticed you have yours sandiched inbetween. This manifold will angle the turbo, and has a seperate port for the wastegate, also at a angle.
http://www.kineticmotorsport.com/products/KINETIC_MOTORSPORT_VW_2L_8V_TURBO_MANIFOLD-467-93.html
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Perhaps a different exhaust manifold. I Nnoticed you have yours sandiched inbetween. This manifold will angle the turbo, and has a seperate port for the wastegate, also at a angle.
http://www.kineticmotorsport.com/products/KINETIC_MOTORSPORT_VW_2L_8V_TURBO_MANIFOLD-467-93.html
I yeah I debated between that manifold and the one I got....it's only about $200 diffrence between the two..lol
I dont know I gotta take some measurments and see whats up...also not sure the 38mm wastegate manifold would/could work with my 40MM wastegate??
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Dear 53 willys,
looks impressive, again nice work.
If it will not fit into your car and you wand to get rid of it, you can just
send it to me :shock: , because i have the car (MK1) were it will fit
(http://i702.photobucket.com/albums/ww24/euro-styler/52ed_1.jpg)
Just for my understanding, i was thinking that your car is allready running. Do you work on two cars, or is that just the evolution 1 setup?
Just for your information, my gasket-to-go mls headgasket it still ok and i run the car (BMW 524 TD) very hard with approximate 26 psi.
Best Regards
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Dear 53 willys,
looks impressive, again nice work.
If it will not fit into your car and you wand to get rid of it, you can just
send it to me :shock: , because i have the car (MK1) were it will fit
(http://i702.photobucket.com/albums/ww24/euro-styler/52ed_1.jpg)
Just for my understanding, i was thinking that your car is allready running. Do you work on two cars, or is that just the evolution 1 setup?
Just for your information, my gasket-to-go mls headgasket it still ok and i run the car (BMW 524 TD) very hard with approximate 26 psi.
Best Regards
hey buddy...I dont have 2 cars...this is just more evolution of the same project.
thats great news about the gasket! they seem to be holding well so far.
Well my cast exhaust manifold is NOT going to fit with my external wastegate spacer...I'm gathering parts to build my own...
PM me if you want a good deal on a t3 exhaust manifold for all 8V VW's...
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well I been ordering parts and waiting...then ordering more parts because the first ones were wrong....so I order more...wrong again...so after 3 try's I finally got the stuff I want to build my Tube header...
this is not a equal length head for 2 reasons...
1. I don't have lots of room..and I don't want the turbo stuffed in there to where I cant access it.
2. this is my first time tig welding SS....so i did not want the headache of arranging equal runners.
so here is what I got so far...
1.5" SS tubing tig welded to a 1/2" steel flange
It takes 2x U-bends to make what I have here....
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0695.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0696.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0697.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0700.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0699.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0698.jpg)
I also got my 11mm pump head!!!! 8) I will have my stage 4 zukgod1 injection pump running soon as I get this header built...
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0701.jpg)
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0702.jpg)
let me know what you think...
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Wow! How are you going to hook that up to the other 2 ports? How stinking hard is it to fab this? At least my mess is flat and something exists to mate it to, but you are going from nothing and have tubes. Making the patterns is what is taking me so long on mine I can't even imagine doing something like this it would take a little bit of forever to get it right...for me I guess.
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Wow! How are you going to hook that up to the other 2 ports? How stinking hard is it to fab this? At least my mess is flat and something exists to mate it to, but you are going from nothing and have tubes. Making the patterns is what is taking me so long on mine I can't even imagine doing something like this it would take a little bit of forever to get it right...for me I guess.
thanks! the other 2 runners will be rough cut and notched...then the VERY time consuming process of fitting them up starts...lots of fitting and grinding...until it's right...the outer runners and collector will stay tacked in place until I have the inner runners notched...
it's not easy to fab this stuff...you need to have a pretty good arsenal of metal working tools. and lots of patience, shoot this is already my second version of it...I had a different set-up all tacked up..only to realize it was not gonna pan out how I wanted...so I cut it all back off...there goes a few hours down the drain..lol
this current style is pretty sweet if I do say so myself. :P
should have great flow...not too big with giant runners=less lag.
I should be able to make the last two runners and finish the collector and weld a couple SS 1/8" bungs(pyro & drivepressure) on it this week....finally some progress!! ;D
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good job on that mani. that looks like a quality piece that i would build. you are a fine craftsman. crap, its not even done, but i can tell its going to be a professional quality piece.
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;D zukgod makin pumps now?
well...he lives real close to me and I'm lucky enough to have him help me with mine....so yes he makes pumps..but I dont know if he is making them for others?? I'm just giving Dan some props for making me a nice running pump the first time around...all the small stuff is done to my pump...now I just need this bigger pump head and I should be set!! sooo yeah my stage 4 zukgod1 pump!! ;D
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oh yea...
if you keep a stock TD manifold on there, with that work of art you call a turbo manifold...
i will slap you.
you can build cool stuff...
build a cool intake too, or at least use a gasser one.
or cut that one up like dave does and build a dual plenum one.
i love daves intakes. they are pretty.
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oh yea...
if you keep a stock TD manifold on there, with that work of art you call a turbo manifold...
i will slap you.
you can build cool stuff...
build a cool intake too, or at least use a gasser one.
or cut that one up like dave does and build a dual plenum one.
i love daves intakes. they are pretty.
haha...yeah I plan on making my own version of the PP intake....pretty much the same design but wont have as nice of welds since I'm not that great at tiging... :P
I just had the stock one on there for a height reference...I will be building the intake manifold soon...the header will fit with the stock intake or the dual plenum intake I will be making..
thanks for the compliments...I'm still learning so I know I can do better..hopefully it turns out ok...
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tig welding isnt that hard. if my retarded ass can tig weld, anyone should be able to. but then again i learned how to tig when i was a freshmen, and it was in a senior welding class. honestly, if you can weld good with an oxy-acetylene torch, you will be good to go with a tig. same basic principal, just with an electric fire instead of a gas fire. although i would need lots of practice with a tig gun before i made anything pretty. its been so long since i welded alot. ***, i used to weld every day it seems like.
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Any action? What are the specs on the charger? turbine A/R wheel trim comp A/R trim? comp map? We all wanna know. And i wanna know how she runs.
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awesome job on the exhaust! did you make the plate yourself or can you buy it pre-made??? are you going to have it ceramic coated?
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Just read this entire thread in 2 sittings. :o WOW I am completely humbled by your build. This car is totally sick. You sir have inspired me to push my aaz swap a little further than I had planned. I can't wait to see where this goes.
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Any action? What are the specs on the charger? turbine A/R wheel trim comp A/R trim? comp map? We all wanna know. And i wanna know how she runs.
I'm at work right now....I will try and post the turbo specs in the morning when I can get to my personal email.
I sold my house and moved this last 2 months...so sadly the vw has been on the back burner while I'm getting the new house set-up and the the shop settled in....it's really been crazy and I have been bumming out on my self for not getting it done yet... :-\
Should have some more updated exhaust manifold pics soon......
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awesome job on the exhaust! did you make the plate yourself or can you buy it pre-made??? are you going to have it ceramic coated?
thanks bud....that header plate came from techtonics tuning (sp?) I was gonna make one but I did not have any 1/2" plate instock and I did not want to buy a big sheet at the time...so I went the easy way out..lol
I might coat it???? have not really thought about it really.....I have had great luck with the cheap 1600* spray paint so.... :-X ;D
naw just joking...I wont high temp paint this header....probably just get some "HPC coating put on it since their shop is only like 10 mins from my house.
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Just read this entire thread in 2 sittings. :o WOW I am completely humbled by your build. This car is totally sick. You sir have inspired me to push my aaz swap a little further than I had planned. I can't wait to see where this goes.
hey thanks bud...it's been a lot of work, time and money for an old car.....I have had a great time building though!! ;D
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got a small update here...
http://vwdieselforum.com/forum/showthread.php?t=6&page=6 (http://vwdieselforum.com/forum/showthread.php?t=6&page=6)
I will post the 2 turbo maps I have as well...
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(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0768.jpg)
http://vwdieselforum.com/forum/showthread.php?p=116#post116 (http://vwdieselforum.com/forum/showthread.php?p=116#post116)
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Deadly :o
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Deadly :o
thanks bud..it's good to finally get back to work on the project....
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got my block mounted oil drain done..
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0772-1.jpg)
more that here..
http://vwdieselforum.com/forum/showthread.php?p=116#post116 (http://vwdieselforum.com/forum/showthread.php?p=116#post116)
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::)
About time...
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::)
About time...
haha.... I know right!?
I have had this car for over a year and only put about 1000 miles on it.. :P
It's getting closer..... :D
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0770-2.jpg)
more updates here aswell
http://vwdieselforum.com/forum/showthread.php?t=6&page=7 (http://vwdieselforum.com/forum/showthread.php?t=6&page=7)
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i think i wanna build a header like yours.
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i think i wanna build a header like yours.
DO IT!! just dont ask me to do it for you ;D...it was a PILE OF WORK!!...I'm just glad it's done..I was working on the down pipe this afternoon and I was thinking the down pipe felt really easy to build after all the crazy notches and fitting of tubes for the header..hahaha
That looks really good. Can you get more of the exhaust flanges? How much?
Thanks Andrew...are you referring to the main header flange?? if you are I just bought this one from techtronics tuning...
http://www.techtonicstuning.com/showpart.asp?partnum=251.290 (http://www.techtonicstuning.com/showpart.asp?partnum=251.290)
I think I paid about $50 for it??
they make it with SS...but the SS version is 4 separate pieces..not all one piece like the 1/2" steel version....
I was kinda scared to try and weld the 4 piece one...I would probably warp it with my welds..
but the real reason I went mild steel with my SS tubing was I did not decide to go with the SS until after I had already received my flange...
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i think i wanna build a header like yours.
DO IT!! just dont ask me to do it for you ;D...it was a PILE OF WORK!!...I'm just glad it's done..I was working on the down pipe this afternoon and I was thinking the down pipe felt really easy to build after all the crazy notches and fitting of tubes for the header..hahaha
why would i ask you to build it? i can cut and weld just as good as the next guy. i built a turbo header for my 19.5 horse briggs lawn mower engine. it has a T3 off a lebaron on it. it doesnt really spool down low at all, but its sure cool having a lawn mower with a turbo, a header, and half of a VW injection system. you should see the look on peoples faces when i fire that thing up and give her some throttle. its just a bit louder than stock with the turbo, and i have a 2.5" tail pipe comin off the turbo. still needs a bit of tuning tho, back fires quite a bit when you let off the throttle.
but yea, i can build it, i even had to build my own flange for this creation, as it has a non-standard T3 flange. except im way more partial to low mounting the turbo down low behind the engine, gives way better clearance and options for intakes and you dont have to have such a god damn down pipe. top mounting the turbo is awesome if you wanna run a hood stack... god i love hood stacks.
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i think i wanna build a header like yours.
DO IT!! just dont ask me to do it for you ;D...it was a PILE OF WORK!!...I'm just glad it's done..I was working on the down pipe this afternoon and I was thinking the down pipe felt really easy to build after all the crazy notches and fitting of tubes for the header..hahaha
why would i ask you to build it? i can cut and weld just as good as the next guy. i built a turbo header for my 19.5 horse briggs lawn mower engine. it has a T3 off a lebaron on it. it doesnt really spool down low at all, but its sure cool having a lawn mower with a turbo, a header, and half of a VW injection system. you should see the look on peoples faces when i fire that thing up and give her some throttle. its just a bit louder than stock with the turbo, and i have a 2.5" tail pipe comin off the turbo. still needs a bit of tuning tho, back fires quite a bit when you let off the throttle.
but yea, i can build it, i even had to build my own flange for this creation, as it has a non-standard T3 flange. except im way more partial to low mounting the turbo down low behind the engine, gives way better clearance and options for intakes and you dont have to have such a god damn down pipe. top mounting the turbo is awesome if you wanna run a hood stack... god i love hood stacks.
haha I don't doubt your skills bud..I was just saying it was alot of work... ;)
well I'm kinda opposite of you on the turbo mounting...no hood stack here..but I also wanna be able to get to my turbo stuffing it down low wont help me out any..and I left plenty of room for my next upgrade..I already mocked a 3" dual plane intake just like the PP ones Dave makes...so I got the best of both worlds with this mounting location IMHO 8)
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a little old school metal working.....
http://vwdieselforum.com/forum/showthread.php?p=122#post122 (http://vwdieselforum.com/forum/showthread.php?p=122#post122)
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Looks bad ass Mark!!
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its gonna be one sweet setup. the low mount turbo is the way to go tho, then when you decide to do compounds, theres plenty of room for the second turbo,
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its gonna be one sweet setup. the low mount turbo is the way to go tho, then when you decide to do compounds, theres plenty of room for the second turbo,
I don't plan on compounds....waay to much boost for our heads....I will wait for someone else to be that geina pig...
Plus I can trim the flange and flip the header for compounds.... ;D
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its gonna be one sweet setup. the low mount turbo is the way to go tho, then when you decide to do compounds, theres plenty of room for the second turbo,
I don't plan on compounds....waay to much boost for our heads....I will wait for someone else to be that geina pig...
Plus I can trim the flange and flip the header for compounds.... ;D
Or is you wanted to be creative you could do like Detroit Diesel does and "turbo-compund" your engine - the second turbo does not run a compressor, but adds power back to the crank shaft - they get 10% more HP free and burn 5% less fuel.
http://detroitdiesel.com/engines/dd15/ (http://detroitdiesel.com/engines/dd15/)
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the only issue I can see with my mounting location is I got the turbo kinda close to the ac lines...gonna have to be creative to get my intake to go by...I will get it though.
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i dont run a/c, so i will never have those problems
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i dont run a/c, so i will never have those problems
I'm a wuss....I need my AC in the Utah dry heat...it's brutal with out. your lucky..
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i dont run a/c, so i will never have those problems
Ya ya ya, you hillbillies up in the PNW dont need it as it hardly ever gets hot enough to warrant. ;D
In Utah however it can be 80+ still at 1am so AC is all but a requirement here...
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dude, trust me, i was wishin i had a/c last year. it was 120*+ last year. my truck would overheat from cold in less than 5 miles. and the humidity was at almost 100%. dry heat is nothing compared to the super moist heat we have here, it just doesnt really get super hot all the time tho. but for the 10 months out of the year when all i use is the heater, who needs a/c? it takes up space, weight, and time. im glad my rabbit doesnt have it, because my intercooler would have never fit with a/c. and as for the audi, it has a/c still, but its un hooked and doesnt work. i need to take it the rest of the way out now.
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I require A/C in my vehicles. Flagstaff is colder than Chicago year round, but you can't leave the island (mountain) in the summer without A/C.
You'll need it if you ever make it down to Davis Mountain AFB to see the Bone Yard.
(http://i533.photobucket.com/albums/ee338/the_arb/bone.jpg)
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arizona heat is nothing. its dry. dry heat is nice compared to here. when its hot here, its hot like florida. over 100* and over 100% humidity. lol
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I would love to get rid of mine...it makes the engine bays looks great..I might even try shaving my bay to nothing...but I gotta have ac..
got my welder hooked up!!! gonna finish my down pipe by tomorrow...maybe even drive the car!! :o 8)
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Yeah im in phx. 120 is 120. grew up in houston so i know what the 100% swamp heat is like.
Its too dam hot! first thing i did to my rabbit was go thru the ordeal of putting ac on a noon ac car.
Build looks good.
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Mark, Text me your new address sir!!
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Mark, Text me your new address sir!!
10-4.....
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sooooooooo close.......
(http://i81.photobucket.com/albums/j240/53willys/1991%20Jetta%20GLI%20diesel%20conversion/DSC_0810.jpg)
more here
http://vwdieselforum.com/forum/showthread.php?t=6&page=7 (http://vwdieselforum.com/forum/showthread.php?t=6&page=7)
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Looks way nice Mark!!
Cant wait for a ride.. 8)
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I don't see why you would ruin a nice GLI by turning it into a diesel.
Ha ha.
Remember all the haters on the vortex that slammed you for it?
I wonder what they would say if they saw it now.
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I don't see why you would ruin a nice GLI by turning it into a diesel.
Ha ha.
Remember all the haters on the vortex that slammed you for it?
I wonder what they would say if they saw it now.
haha yeah the purist on Vortex were actually pretty mad at me....now my stinky little diesel would probably blow the doors off most 16v gasser's... ;D
the turbo and down pipe are on!!! I ended up having to order a 3.0"-2.5" 90* silicone elbow for my intake...probably wont get it until thursday with the holiday on monday :'(
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ITS ALIVE!! ;D
I got it started but two of my rebuilt injectors are leaking between the two body half's... >:(
I guess I will take them back off and snug up the body some more??
now soon as my silicone elbow shows up I can drive it!!! ;D 8) (long as my injectors stop leaking)
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im curious to see how that header and turbo work...
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im curious to see how that header and turbo work...
ME TOO!!! I'm going nuts...kinda hard to sleep I'm so excited..hehehe
I TQ'ed the injectors down to 60ftlbs and they quit leaking....it's idling smooth and ready to rock....just need my dang 2.5x3 90*
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We want full boost launches! 8) Lots of video and comments on spool. What size is the turbine housing and wheel?
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We want full boost launches! 8) Lots of video and comments on spool. What size is the turbine housing and wheel?
oh dont you worry I will have lots of vids....dyno and drag race....
I'm a little embarrassed to say I forget the turbo specs right now...I know its a 50 trim .48 AR...but I cant seem to locate my build sheet since moving a month ago..my files are kinda scattered...
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oh yeh I just tracked my 90*elbow it should be here tomorrow sometime!!! 8) 8)
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UPDATES!! I see a thread about changng coolnt systems and still no vids of full boost launches!!!!!!!
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UPDATES!! I see a thread about changng coolnt systems and still no vids of full boost launches!!!!!!!
One word...
SMOKE!!!!!!!!!!!!!!!! ;D ;D ;D
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I found out my wastegate was leaking and causing spool up issues... :P
Should have some more news to report in a day or so....
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53 willys I am soo impressed with your build!! I was told about your head gasket since I wanted to go above the 20 lb mark w/o blowing my head gasket... I still need to measure the piston protrusion above the deck so I know what thickness of a gasket I need. I had a 3 notch before I rebuilt the short block.
Any way... I have been pickin' away at your thread with the 5 minutes here and there... Man I am excited to see it finally working!! This has been like one of those good books that you get to read, and once you get to a certain point you don't want to put it down... I am runnin' late for work so I could finally finish the thread. Would've been sooner, but I just didn't have the time to read!!
Just to join the rest... uuhhh where's the video?
Zukgod... I wanted to talk to you on the phone... can you IM me your cell? I wanted to ask you a couple of things about my project... (sorry to ask that on your thread 53...) It's about my pump... and Giles...
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Zukgod... I wanted to talk to you on the phone... can you IM me your cell? I wanted to ask you a couple of things about my project... (sorry to ask that on your thread 53...) It's about my pump... and Giles...
PM Sent
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well....I came across a smoking deal on a installed but never used NOS system..they guy bought it for his show car and never even filled it with nitrous!
probably should have bough a radiator instead....BUT I have been wanting some drugs for awhile so I could not pass it up....probably blow something up for sure now...lol
this build is slowly getting less and less daily driver friendly....hahaha
waiting on some more injector heat shields...then i can update my cooling issues..
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Hey man... what did you do about your gas tank with the diesel?
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Though I live in Guaymas, Sonora, Mexico...I maintain a post office box in Tucson Arizona (my legal US address..no more upstate NY). There has been the odd occasion I've driven up to retrieve something from my box, only to find I have to wait a day. Well, my box is on Valencia Rd, so why not kill a little time and drive on over to Davis Mothan AFB....the bone yard is incredible. There is also a guy in one of the industrial parks close by that has a number of MK1 Diesels in his yard. But, he's never there when I stop in.
Ok, that said, I've been following this GLI to 1.6TD conversion from the beginning.
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Any progress? Ever find the turbo specs? When does full boost hit? Do you still have your cast manifold?
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well I finally got around to doing some more tuning and tweaking...
had to put a lighter weight spring in my wastegate..it was never opening....now I got it set to 20psi so I can break everything in..the more I drive the T-3 ball bearing turbo the faster it spools..it getting really nice.
the 11mm pump is REALLY REALLY smoky..and at 20psi it's STILL ROLLING COAL...lol I'm gonna start backing the fuel down so I can clean it up.
as for water temps..I took the ac condenser out..and all the tubing..I also put a super low temp t-stat in and now even when I romp it hard it wont go past 185*(temps outside were 45*) 8) 8)
I'm not sure the ac will go back in or not???
I also have 1 injector that keeps leaking..I cant really tell if its the small nipple on the return line or the flanged nut/seal...more checking on that..
I will get some vid up ....but I want it running right before I take the time to film it....it's really really close right now!!
I still have not installed my Volvo oil cooler either..i somehow lost the filter nipple extension when I moved a few months back...now I gotta go find another junkyard Volvo and get the nipple off it..but pulling parts in a Pick n pull in the snow is not something I'm in a hurry to do...lol
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53 willys I am soo impressed with your build!! I was told about your head gasket since I wanted to go above the 20 lb mark w/o blowing my head gasket... I still need to measure the piston protrusion above the deck so I know what thickness of a gasket I need. I had a 3 notch before I rebuilt the short block.
Any way... I have been pickin' away at your thread with the 5 minutes here and there... Man I am excited to see it finally working!! This has been like one of those good books that you get to read, and once you get to a certain point you don't want to put it down... I am runnin' late for work so I could finally finish the thread. Would've been sooner, but I just didn't have the time to read!!
Just to join the rest... uuhhh where's the video?
Zukgod... I wanted to talk to you on the phone... can you IM me your cell? I wanted to ask you a couple of things about my project... (sorry to ask that on your thread 53...) It's about my pump... and Giles...
thanks for the kind words deepgroves!!
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You can buy those fittings.
I was searching info on volvo oil coolers,
over on the vortex when I was installing mine.
,.. and they had thread sizes and links to the fittings.
Seems like summit had them.
I probably have a spare around, since I used AN fittings on one.
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as for water temps..I took the ac condenser out..and all the tubing..I also put a super low temp t-stat in and now even when I romp it hard it wont go past 185*(temps outside were 45*)
I'm not sure the ac will go back in or not???
I happen to need a condenser and all lines for my 86. Let me know if you will not be using them as I would probably find a home. Good luck on the rest of your project and video...can't wait to see it.
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You can buy those fittings.
I was searching info on volvo oil coolers,
over on the vortex when I was installing mine.
,.. and they had thread sizes and links to the fittings.
Seems like summit had them.
I probably have a spare around, since I used AN fittings on one.
thanks for the help...but I need the oil filter nipple not the oil cooler nipples...I think I got it figured out though...I gotta do some lathe work to make one of the adapters I had laying around work.
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as for water temps..I took the ac condenser out..and all the tubing..I also put a super low temp t-stat in and now even when I romp it hard it wont go past 185*(temps outside were 45*)
I'm not sure the ac will go back in or not???
I happen to need a condenser and all lines for my 86. Let me know if you will not be using them as I would probably find a home. Good luck on the rest of your project and video...can't wait to see it.
I'm gonna keep it...I still would like to keep the ac and make it work..but just not gonna mess with it at this time. 8)
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as for water temps..I took the ac condenser out..and all the tubing..I also put a super low temp t-stat in and now even when I romp it hard it wont go past 185*(temps outside were 45*)
I'm not sure the ac will go back in or not???
I happen to need a condenser and all lines for my 86. Let me know if you will not be using them as I would probably find a home. Good luck on the rest of your project and video...can't wait to see it.
why didnt you tell me this a while ago? i would have saved all my a/c components and gave them to you. but instead i kinda destroyed some of the stuff getting it out.
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I sure am getting old waiting for you to finish this Mark ;D
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wow just saw this thread...
i gotta say, i am completely envious, and the funny thing is tonight i got on the site to do a search if anyone had tried one of these turbos yet...
i was actually looking at a .60 trim T3 but im very curious to see where your 50trim spools at. i assume you have a tach so you can tell?
your build is very very similar to what i will be doing this spring. btw, is that just an 11mm home-modded pump or is it a full giles?
Very nice setup, i hope it lives up to your expectations and mine as well and very very nice workmanship 8) 8) 8) 8) 8) 8) 8) 8) 8) 8)
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How about the videos??? I want to see and hear this thing. It will give me inspiration to work on mine again. Help a fellow Veedubber out. ;D
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wow just saw this thread...
i gotta say, i am completely envious, and the funny thing is tonight i got on the site to do a search if anyone had tried one of these turbos yet...
i was actually looking at a .60 trim T3 but im very curious to see where your 50trim spools at. i assume you have a tach so you can tell?
your build is very very similar to what i will be doing this spring. btw, is that just an 11mm home-modded pump or is it a full giles?
Very nice setup, i hope it lives up to your expectations and mine as well and very very nice workmanship 8) 8) 8) 8) 8) 8) 8) 8) 8) 8)
whats your altitude???....for the altitude I drive in I wish I could have got a 45trim..witch is what they originally speced me on and then told me they had discontinued the 45trim...
i'm at 4000-5000ft above sea level most the time and my turbo spools pretty fast but not as fast as I like...the real nice thing I find with the BB turbo is not much boost lost on shifts so you can keep it spooled once you do get it there...
now that I have another few tanks on this 11mm pump I really feel it's too hot and smoky for my app...I can turn it all the way down and it still smokes pretty dang hard...I think a 10mm or even a 9mm might work better...? :o
my car is still a work in progress and it has been a long hard road but I do like the way it runs....it's getting better everyday it breaks in more.....
thanks for the complements. 8)
Btw Zukgod1 on here is the man who did my pump...he's the man. 8)
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How about the videos??? I want to see and hear this thing. It will give me inspiration to work on mine again. Help a fellow Veedubber out. ;D
I know brother....I gotta empty my drive on my camera....so I can make a vid for you...I been saying I would for like 4 months... :P
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Mark,
I think I may have a 9mm pump at home if you want to try a smaller one..
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Mark,
I think I may have a 9mm pump at home if you want to try a smaller one..
yes.......please.. ;D
I will get in touch with you.....probably better wait until I have your g60 cover in gloss black.... :-[ :-[ :-[(still sitting in my shop un coated... :-[ :-[ :-[
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wow just saw this thread...
i gotta say, i am completely envious, and the funny thing is tonight i got on the site to do a search if anyone had tried one of these turbos yet...
i was actually looking at a .60 trim T3 but im very curious to see where your 50trim spools at. i assume you have a tach so you can tell?
your build is very very similar to what i will be doing this spring. btw, is that just an 11mm home-modded pump or is it a full giles?
Very nice setup, i hope it lives up to your expectations and mine as well and very very nice workmanship 8) 8) 8) 8) 8) 8) 8) 8) 8) 8)
whats your altitude???....for the altitude I drive in I wish I could have got a 45trim..witch is what they originally speced me on and then told me they had discontinued the 45trim...
i'm at 4000-5000ft above sea level most the time and my turbo spools pretty fast but not as fast as I like...the real nice thing I find with the BB turbo is not much boost lost on shifts so you can keep it spooled once you do get it there...
now that I have another few tanks on this 11mm pump I really feel it's too hot and smoky for my app...I can turn it all the way down and it still smokes pretty dang hard...I think a 10mm or even a 9mm might work better...? :o
my car is still a work in progress and it has been a long hard road but I do like the way it runs....it's getting better everyday it breaks in more.....
thanks for the complements. 8)
Btw Zukgod1 on here is the man who did my pump...he's the man. 8)
you can get the GT2554R and GT2560R (28r) in T3 externally wastegated, im looking into both of these options.
btw F the vids, i want a dyno!
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for the love of god!! WE NEED UPDATES!
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for the love of god!! WE NEED UPDATES!
update...my front cooling flange is old and pitted....it's keeps causing coolant leaks...I'm afraid if I go any tighter with the hose clamp it's gonna cut right through the hose...probably gonna have to pick up some new one's...
also noticed I have a small trans leak...about the size of a soda can after sitting for a day or so....
there you go....I do have a feeling thats not the kinda update you wanted...? ;D ;D
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***! haha....
do you plan on hitting the dyno? do we need to gather a pool together? lol
we will have to compare dynos this summer as our builds will be very similar. ive been looking hard into using either the GT2554 or the GT2560(28r) so our snails will be similar in size. I found a guy that can make me a passenger performance style intake manifold locally, and of course there will be the beefy giles pump.
can i ask you where you got your cometic gasket made? i think i will do the same
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***! haha....
do you plan on hitting the dyno? do we need to gather a pool together? lol
we will have to compare dynos this summer as our builds will be very similar. ive been looking hard into using either the GT2554 or the GT2560(28r) so our snails will be similar in size. I found a guy that can make me a passenger performance style intake manifold locally, and of course there will be the beefy giles pump.
can i ask you where you got your cometic gasket made? i think i will do the same
yeah I will be on the dyno this spring....and the 1/4 strip with it....still need to get my nitrous kit hooked up but I been to busy with other projects...
I dont expect much on dyno numbers...? my altitude is gonna kill it I got a feeling??
150-200hp would be cool :o...hopefully it does not take drugs to get that number?? maybe pop another 10-15hp with a small shot??
we will see.....I'm kinda thinking i'm gonna need some water injection to make a full 1/4 pass with out hitting 1500*!!!!!
my MLS gasket came from the only place I could find that would make one for a VW diesel...
gasketstogo.com (http://gasketstogo.com) they are in Thailand!! ;D
if you search the blog with "vw" you can read about the gasket.....
what size do you need??
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what were the specs on yours? im sorry if it was gone over already...
is it compression dropping?
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what were the specs on yours? im sorry if it was gone over already...
is it compression dropping?
mine is a 2 hole....and no on the oversized gasket...my piston protrusion called for a 2 hole so that what I did.
I got a spare 3 hole I might sell you...I think I should have just got a spare two hole instead.... so if I sell it I wold just order a new 2hole....
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did you consider dropping the compression at all? or no because you live in a cold high elevation climate?
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did you consider dropping the compression at all? or no because you live in a cold high elevation climate?
yeah you guessed it....to cold in the winter and too much elevation. :(
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i might pick that gasket up from you, i found a rebuilt shortblock i want to get that requires a 2hole. ill let you know if i decide to purchase it.