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Engine Specific Info and Questions => Non VW Group Diesel => Topic started by: jimfoo on May 04, 2007, 01:47:58 am

Title: 1.9 Rover re-install
Post by: jimfoo on May 04, 2007, 01:47:58 am
Some pics of my re-install as I rebuild everything after my crash.
(http://www.66rover.com/rover%20rebuild/seng_tran1.jpg)
The IP side of the engine. The remote filter adapter is visible.

(http://www.66rover.com/rover%20rebuild/seng_tran2.jpg)
The turbo side with my 2.5" re-routed exhaust visible.

(http://www.66rover.com/rover%20rebuild/stran_eng.jpg)
Looking from the tranny end. You can see my k-14 manifold to GT1749 adapter, and the EGT port in it. I left room on top for an external waste gate if I decide I want one.
Title: All current pics of rebuild
Post by: jimfoo on May 05, 2007, 01:53:14 am
I have all my pics and a short QT7 movie here.
http://www.66rover.com/rover%20rebuild/index.html
I will update as I get more work done.
Title: 1.9 Rover re-install
Post by: jtanguay on May 05, 2007, 05:03:48 am
hehehe listen to that whistle!!!
Title: 1.9 Rover re-install
Post by: foxracer1 on May 05, 2007, 10:41:21 am
Your VNT controller looks good I think i'm going to find some flanges that will work. Did you say the 15 controller is different than the 17?
Title: 1.9 Rover re-install
Post by: jimfoo on May 05, 2007, 11:07:04 am
What's pictured is the 15 actuator. The 17 has a different linkage that snakes around a lot. My actual controller isn't built yet as it will be based on Named TinTin's design. In case you don't know, the stock actuators work off vacuum, so have to be modified to work off of boost. There is an old thread on here somewhere by fspgtd that details it. He machined a nice aluminum ring to hold the 2 halves together. I went the cheap route when I found that 2.5" header flanges are a perfect fit.
Title: 1.9 Rover re-install
Post by: foxracer1 on May 05, 2007, 12:07:56 pm
Yeah i studied that very long thread several times. So how hard are the 17 controllers to find? I guess if the 15 won't work on that center section then i won't open it up. I'll just find a 17 controller.
Title: 1.9 Rover re-install
Post by: jimfoo on May 05, 2007, 12:32:30 pm
It's not that it won't work, it just depends on how you mount it. You could make it work one way or another. The 17 actuator mounted under the turbo towards the block, and the 15 mounted under but away from the block. I probably won't be using the 17 actuator, so let me know if you will need it.
Title: 1.9 Rover re-install
Post by: foxracer1 on May 05, 2007, 02:31:32 pm
So after flipping the spring it sets the vanes in full boost(closed) all the time right? Until the boost rises then it begins to open them. So while idleing the vanes with be at max boost correct? Now i wouldn't see this as a problem when the car is cold as the back pressure and extra air would aid in cold running. But it seems you would want it to open when idleing warm so the heat would decrease more(faster). Does this sound crazy or just hard to make it work?

jimfoo i'm still waiting on the transfer. But if you didn't mind i would like the actuator with it. Just so i have options.
Title: 1.9 Rover re-install
Post by: jimfoo on May 05, 2007, 04:24:13 pm
It wouldn't make that much difference when idling, but when cruising at less than close to full boost, it would be restrictive. Plus if you ever blew a hose off, the turbo would be making max boost with no wastegate to regulate it
unless you put an external one on. I did buy one, but will wait to see if I need it or not.
Title: 1.9 Rover re-install
Post by: foxracer1 on May 09, 2007, 09:45:03 pm
After thinking about it for a while and seeing the pics you had up. i understand now. I feel this is a very effective way to set it up. looks good and  i feel i will be mocking this set up.
Title: 1.9 Rover re-install
Post by: jimfoo on June 05, 2007, 09:06:47 am
A few pics of my current progress

(http://www.66rover.com/rover%20rebuild//060407/slides/PICT0315.jpg)
This is where the cables hook to the pedal linkage. Vane control is on the left,    throttle on the right.
(http://www.66rover.com/rover%20rebuild//060407/slides/PICT0316.jpg)
This is the bracket on the other end. The cable on the right is for manual vane control, and is from an old choke cable. The nice thing about it is that it has a switch built in to let you know it's on. The bad thing is that when boost is reached and the actuator opens the vanes, it pulls the cable back somewhat, so I may have to buy a locking one instead. I have it as I think I may want faster response when off-road.
(http://www.66rover.com/rover%20rebuild//060407/slides/PICT0317.jpg)
This is how the 2 cables connect to the fane control cable. The manual control has 2 springs to limit the required knob travel.
Title: 1.9 Rover re-install
Post by: jimfoo on June 05, 2007, 09:13:42 am
Some more pics.
(http://www.66rover.com/rover%20rebuild//060407/slides/PICT0318.jpg)
My oil coolers, lexan fan shroud and fan.
(http://www.66rover.com/rover%20rebuild//060407/slides/PICT0319.jpg)
My final turbo plumbing. It's amazing how my once roomy engine compartment is getting filled up.
(http://www.66rover.com/rover%20rebuild//060407/slides/PICT0320.jpg)
My Saab intercooler. I'm not quite sure how to mount it yet, but it probably will involve welding aluminum plate on it, like I did for the radiator. I am also probably putting a small fan in front of it.
Title: 1.9 Rover re-install
Post by: deepmud on June 06, 2007, 05:22:06 pm
FWIW, I had a similar intercooler on my old Renault 2.1 TD Cherokee - I always felt that making the air do all that bending around to get in and out of the intercooler made  it restrictive - I'd recommend a DSM intercooler from EBAY (sometimes less than $25) or I even spotted another massive volvo unit like mine today.
(http://i13.ebayimg.com/06/i/000/a3/51/9475_1.JPG)
http://cgi.ebay.com/ebaymotors/Intercooler-from-volvo-great-for-project_W0QQitemZ320123879703QQihZ011QQcategoryZ33742QQrdZ1QQcmdZViewItem

I realize bar and plate is more efficient, but the tube/fin this big will cool efficiently and be low restrictin because if it's size.

Also you need to get the intercooler up close to the radiator to get good airflow between the two - big gaps will let the intercooler tend to block air from the radiator.

The Pachyderm Pursuer will ride again! :D
Title: 1.9 Rover re-install
Post by: jimfoo on June 06, 2007, 10:20:55 pm
It is all 2.5" tubing to the IC except where it has to neck down for the turbo and intake, so I don't think it will be too restrictive. I am planning to put a small fan with its own shroud in front of the IC so that it gets airflow even if the engine fan is off. If I find it doesn't seem that effective, than I may change it later.
Title: 1.9 Rover re-install
Post by: deepmud on June 06, 2007, 11:10:27 pm
the tubing looks great!
The intercooler itself will have some pressure drop. For instance, I tried my 2.1 TD without the intercooler - at 6 or 7psi 65mph cruise, it was a slight increase in economy - but at 10 psi I felt the power loss. But it should be pretty effective for it's size at lower flow rates, I think.

Can't hurt much $$ to experiment, you are using sensible Ebay parts and rubber hoses rather than multi-hundred dollar custom intercooler and silicone hoses :D

I really look forward to hearing how the VNT works for you over the K14 - I hope you get all the low rpm power and greatly increased high rpm flow/economy.  8)
Title: 1.9 Rover re-install
Post by: jimfoo on June 06, 2007, 11:44:51 pm
I can see a slight increase of boost at idle with my manual vane controller closing the vanes. It reaches full boost very quickly even just revving it for a second in the garage. I can't do it much though as it starts filling with black smoke.  :twisted: Right now it looks like the actuator opens the vanes at 14 psi. After I get it on the road, I'll see where I want to go from there. I started on the wiring, getting the stock fuse box mounted(2 fuses) and the ignition switch hooked up. EGT and boost are hooked up, but I don't have power going to the rest yet. Still, it shouldn't be too many more days, weather permitting. I still have to paint some, so if the predicted 90 mph gusts don't calm down, I won't be able to put any more body parts on.
Title: 1.9 Rover re-install
Post by: tom w. on June 11, 2007, 12:19:20 am
can't wait to see your progress
Title: 1.9 Rover re-install
Post by: jimfoo on June 11, 2007, 01:42:23 pm
Quote from: "tom w."
can't wait to see your progress

http://www.66rover.com/rover%20rebuild/index.html shows all the work from the beginning of the rebuild.
The numbers are the dates of the photos, so most recent ones are at the bottom.
Oh, and my original install is here: http://www.66rover.com/VW%20TD/VW%20TD.html
Title: 1.9 Rover re-install
Post by: tom w. on June 11, 2007, 03:37:15 pm
beauty, eh..
Title: 1.9 Rover re-install
Post by: jimfoo on June 18, 2007, 08:59:43 am
I made it out of the garage yesterday!!!! I really couldn't drive anywhere though as I was standing on the frame. :lol:  Once outside, I started putting the tub on, but found my gas tank  skidplate  was hitting a bolt, keeping the tub from going where it needed. I got it within 1/2" of being where it needs to be, so my mission today is to fix that, get the seat box in, fenders and all lights on and get it on the road. I will still need to finish painting, but that can come a little later. I did have a small setback when I went out yesterday morning and saw that my nicely painted footwell had a bunch of bubbling and peeling paint. It seems that my brake master had decided to leak, or maybe it had been that way, but I had forgotten as it had been so long since it had fluid in it. Luckily I had a spare. I have more pics, but haven't uploaded them yet. I still need to decide where to put the oil filter and how to run the intake tube to the air filter and future snorkle, but the fenders need to be on to make sure I have clearance. I can't wait to get it on the road though as that engine sure revs nice!  :twisted:
Title: 1.9 Rover re-install
Post by: jimfoo on June 19, 2007, 08:49:05 am
I did a few test drives down my dirt road today, as I'm not quite legal for the pavement yet. First one was ok, nothing spectacular, but I was having to pay attention to Jen's continual pleas to slow down.  :twisted:  So I dropped her off and took another, this time paying attention to everything else. Lots of black smoke, EGT 1200, 5-7PIS boost, hmmm. Went back home, put the hand throttle on and started checking things. I either didn't tighten a clamp on the IC enough, or had it in the wrong place. So I fixed it, checked the other connections and went for another. BOY!!! 3rd gear, coming back and I punch it. The boost quickly climbs, and all of a sudden I'm fishtailing! SWEET!!! With my old engine I had a hard time spinning the wheels on dirt in 1st. Now to finish getting it roadworthy.
Title: 1.9 Rover re-install
Post by: tom w. on June 19, 2007, 11:21:31 am
haha man that's good to hear
Title: 1.9 Rover re-install
Post by: deepmud on June 19, 2007, 11:31:38 am
yeah, baby! :D
Title: 1.9 Rover re-install
Post by: tom w. on July 03, 2007, 04:06:07 pm
where did you get the remote mount oil filter setup?
Title: 1.9 Rover re-install
Post by: jtanguay on July 06, 2007, 11:59:13 am
Quote from: "tom w."
where did you get the remote mount oil filter setup?


i see them all over the net, but i have yet to find a place that sells to Canada!!!!! argh

search for 'vw oil filter relocation'
Title: 1.9 Rover re-install
Post by: jimfoo on July 09, 2007, 12:12:53 pm
I just ordered it from my local auto parts store.