VWDiesel.net The IDI, TDI, and mTDI source.
Engine Specific Info and Questions => IDI Engine => Topic started by: kaneb on February 07, 2009, 05:11:52 pm
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**Edit*** Thought i would update this as lots have changed since last spring for the little diesel. Updated below!!
heyo,
This past week i have taken off the intake and exhaust manifold, oil pan, oil filter flange. Then painted a couple little things for when i do the the actual 1.6TD swap once the engine is built(probably next fall). Then i cleaned up a wiring mess. Put in new battery cables. I had some issues since I dont think my TD came with all the hoses for the oil cooler, after checking my bentley i made some other lines up. Cleaned up the turbo, exhaust manifold,intake mani. oil filter flange. oil feed and return lines and pan. It started no issues. Had some fun making the intake. Its not perfect still have some bugs to work out. I still have my boost and egt gauge to install(egt probe is installed) Hunting for a tach right now then to tune the engine alittle better once i know how its running. Then onto the 3" turbo back exhaust and intercooler. Then everything is set-up for once my TD is built.
Here's a few pics and a video of how its running. Oh ya, in the midst of redoing the interior a little sneak peak of the seat. The car is now on coilovers. Still looking for some 13X8" wheels for the car.
(http://img.photobucket.com/albums/v393/kaneb/IMG_3777.jpg)
(http://img.photobucket.com/albums/v393/kaneb/IMG_3775.jpg)
(http://img.photobucket.com/albums/v393/kaneb/IMG_3773.jpg)
(http://img.photobucket.com/albums/v393/kaneb/IMG_3745.jpg)
(http://img.photobucket.com/albums/v393/kaneb/IMG_3779.jpg)
Kane
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Here is a two Videos. One is the first time we started it other is after and a couple of kinks are worked out. note-There is no exhaust just the short 8" stock turbo down pipe. hence smoke coming out of the engine bay.
Also i noticed if i gave it a hard pull when driving and the boost went up and then let off throttle the boost would still be up and not enough fuel causing the engine to stall. turned up the injector pump(NA pump still) Its all fine. Idles high though. Guess it will have to for now?
http://smg.photobucket.com/albums/v393/kaneb/?action=view¤t=MVI_3770.flv
http://smg.photobucket.com/albums/v393/kaneb/?action=view¤t=MVI_3778.flv
Kane
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that starts up real nice and quick. but maybe a couple bad GP's...
you'll have to play around with the pump to get rid of that hanging idle though... its not bad, but its not good either. did it do that before you upped the pump?
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yes, it always has hung a bit, is that repairable? The NA pump is working, but i would like to find out if its possible to switch the boost enrichment from my TD pump to my NA since the NA has been well maintained.
Kane
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So car was running great. Temps down, boost and egt all wired in. Egts is around4-6s Very low, probe is tapped into exh. mani. Running about 8-10 psi of boost.
My problem is car idles really good after start-up and i let it warm up. Then ill take it for a alittle rip, get through 1st,2nd and into 3rd then it coughs, and bucks and eventually stalls, unless i pump the throttle and sometimes i can get it to not quite stall it will then take a mintue or two to get the idle even back out. I'm thinking air is getting into the fuel system. Fuel filter has been changed recently, timing is good. I would say the pump cant deliver enough fuel when under boost. But it was delivering fine. Last week it was+4 around here andd now its like -8 and this morning -14. Just so you know about as much info as i can give you. It could also be my IP i was trying to tune it to give the car more fuel for when under boost, but also tried turning the idle down so it doesn't idle as high. But after running into this problem put it back to where it was, and same problem.
Any help and opinions appreciated. Want to have this thing running like a champ when it warms up!
Thanks--Kane
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HOLY INTAKE HOSE!!!!
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The oil separator (hockey puck on the valve cover) won't work properly tipped on it's side. It is supposed to drain oil back into the valve cover and can't in that orientation.
Andrew
Good to know, ill get that fixed up. Thank you.
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I have one off my TD. Ill have to pick up a gasket and throw that on.
Anyone have any insight on my fuel issues?
Kane
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So the issue there in the spring was my fuel filter is a spin on and somehow became loose and was sucking air, so i got that fixed up and the little bastard has been running great ever since, even hit 18 psi of boost but just for kicks and brought it back down.
I'm just getting ready to get the TD built should have an engine stand here in the next few weeks. I did 2.5" exhaust in the spring. With plans to do a 2.5 or 3" DP this winter. Just picked up a mazda 626 intercooler today. Have a plan to make my own boost controller for around 10$
Still to buy for engine.
-injectors or rebuild mine
-arp head studs
-1.9 metal HG
-Re-seal kit for IP. I have two TD Ip's but the one that leaks is looking like the candidate for the engine.
-piston rings.
-timing belt/tensioner
-gasket/seal kit
Here is how the car is looking.
(http://img.photobucket.com/albums/v393/kaneb/DSC_0048.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0004.jpg)
(http://img.photobucket.com/albums/v393/kaneb/rabbiteuro.jpg)
And an interior shot that my wife all did for me!
(http://img.photobucket.com/albums/v393/kaneb/DSC_0007.jpg)
Since we all love diesels i think we can appreciate a 7" stack haha
(http://img.photobucket.com/albums/v393/kaneb/DSC_0012.jpg)
Updates will be more frequent in the coming weeks/months.
Also, Anyone running a mazda 626 intercooler on their diesel, or have opinions on them? The size and having the outlets on the same side is a huge plus for my plans and pipe routing in the engine bay. Other then that i have no idea how good it is!
Thanks,
Kane
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Engine will be CAT theme, just for kicks.
(http://img.photobucket.com/albums/v393/kaneb/DSC_0001-2.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0002.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0003-1.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0005.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0006-1.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0007-1.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0008-1.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0009.jpg)
I haven't ordered anything for it yet just pulling it apart. I'm still doing some shopping from where to order from as i would prefer german parts.
I've been looking online mostly.
Kane.
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HOLY INTAKE HOSE!!!!
its amazing the boost to be had from going with a huge turbo intake.
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I do heavy diesel mechanics for a living all hwy rig's. So the piping is made up of air to air piping and such. It may be over the top but thats the plan for the car. It's a wannabe truck... hence going with a cat theme. The big intake is fun. Probably move it to the rain tray as i want to run my intercooler piping where the intake is.
Is there good air flow in the rain tray? I would think it would be cooler there since it's more isolated from the engine bay, Thoughts?
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i got more power when i moved my intake to the rain tray. it worked for me so i dont know why it cant work for you.
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The only thing I would be concerned about would be sucking up water from the rain tray, (think about its name, its wet! its basically a gutter!) It would have a supply of fresh, cool air there though, and its close to the turbo. Just my thoughts.
Travis
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The only thing I would be concerned about would be sucking up water from the rain tray, (think about its name, its wet! its basically a gutter!) It would have a supply of fresh, cool air there though, and its close to the turbo. Just my thoughts.
Travis
you do raise a very good point, practically all the water from the front half of the car winds up there one way or another... You would have to work out some sort of ducting.. I dunno how you would do it.. probably not the best design for those of us in wet climates. lol
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Nice job on the seats. Where did you get the covers from or did you make them yourself? I can't find a decent set of blues ones anywhere other than the cheap thin ones from Autozone and such and even then there is the latch for the seat back release (2 door) to deal with. Where did you find them and if you did make them you did a very nice job ;)
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Hi. How about a pic of your Intake/Fuel filter solution??
I need one.
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Although the heater blower motor is in the rain tray, (and the ecu on gassers?,) so it probably would be posible with the right rigging, although the required rigging might make it restrictive? You could always punch threw the firewall and suck air from under the dash!, although that could make it hard to keep the interior warm, and youd have to drive with a window at least cracked? Im not trying to blow your idia, I just dont like Hydrolocked motors!
Travis
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My plan is to have a very discreet type scoop/vent on the right fender then isolate the rest of the intake from the rain tray. Eventually...at first it would just sit in the rain tray till i get my plan figured out so it looks nice still. The filter would have to be sitting in a puddle to get the engine hydrolocked, maybe i will do a test run at the wash bay just to be safe 8)
Rabbit TD- the seat's were re-done by my wife. She hand sewn them, i helped with the door cards and headliner. They aren't perfect but i have maybe 50$ into the fabric and stuff from fabricland, this is just my fun car and wanted a plaid interior.
Dennis- I may or may not have a photo but i will take one in the next bit when im out in the garage. i pretty much just moved the filter from its bracket over. So it's held on with one stud instead of two to make room(temporary until i get the new engine in and clean the bay up)
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No problem. I'll figure out something. Im not too proud to use someone elses idea though.
Thanks
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Here's an old picture, the day after i put the turbo bits on. Don't mind the vent off the valve cover, it's fixed up now.
The fuel fitler here is just temporary, but it works without any issues. Re-locate soon.
(http://img.photobucket.com/albums/v393/kaneb/IMG_3773.jpg)
Hope that helps.
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Yeah that helps. think I will do what you did but use a piece of metal utilizing both of the mount studs that extends over to where you got yours using both holes.
Thanks
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It's just on there with the one stud. Its fine, I would prefer both of course but for now its good.
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The only thing I would be concerned about would be sucking up water from the rain tray, (think about its name, its wet! its basically a gutter!) It would have a supply of fresh, cool air there though, and its close to the turbo. Just my thoughts.
Travis
you do raise a very good point, practically all the water from the front half of the car winds up there one way or another... You would have to work out some sort of ducting.. I dunno how you would do it.. probably not the best design for those of us in wet climates. lol
i live in oregon, on the coast. it rains 300 days a year. my car never inhales water. well, never enough to hurt it or for me to notice. only time you really get much water in the rain tray is when your car is idling stopped, or at very low speeds. so its not really a problem. besided, the water runs to the floor of the rain tray then out the drains.
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Funny. Doesn't seem to bother the heater blower either.
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what in the world is that intake mani from??? ??? I want one, I was thinking the same thing, in fact I have already removed part of the tray for just this purpose, and also It makes it easier to remove the head from the engine bay without having to remove the exhaust and intake.
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well once it's a little warmer ill be Working more on the bottom end. I was just going to replace the rings, but since it's apart i am going to do it all with all new bearings going with kobleshicmt(sp??) and the rings i'm not sure the company name. I have to hone the block then ill order those parts, I doubt ill have to over size the ring after honing, but im not risking it.
For now though i just picked these up.
(http://img.photobucket.com/albums/v393/kaneb/16647_202925957340_506177340_366691.jpg)
New gasket kit and arp head studs. Arp studs is probably over building it but thats better then under. .
Getting stoked for this little guy. Was pondering about doing a 3" DP and putting in an exhaust brake just to be a tard but i think i'd blow the 1.6 up, plus i don't require it at all. And have other things i could buy. Just thought it would be hilarious for such a little engine. Also im all about going over the top with this.
Quick question, as this is my first time really ripping into a vw engine. I've worked on hwy trucks, mostly international dt466, and assisting inframes on cat c-12's, cummins isx etc. I have the hydraulic lifters, and they have gotten mixed up and the bentley says to keep them in the same order etc. Is it just the solid lifters that need to be shimmed, thus need to be left in the same order or does the hydraulic ones need to be too? Still a newbie on this so thanks in advance!
Kane
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Hydro ones don't need shimmed ever.
I think the reason for not mixing them up is for the sake of the lifter bores and cam lobes, so it doesn't have to "wear in" more times than necessary.
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what in the world is that intake mani from??? ??? I want one, I was thinking the same thing, in fact I have already removed part of the tray for just this purpose, and also It makes it easier to remove the head from the engine bay without having to remove the exhaust and intake.
what intake? the intake on kanes car is stock, and the one on my car is a digi 2 gas intake.
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The lifters and the cam wear together big time. If you mix up your lifters chances are you're going to toast your cam in pretty short order. Essentially the cam lobes get a bit of a dish to them that matches the specific lifter it was running on.
Other thing is the hydro lifters DO wear out - given that they're only about $10 each if I were in your shoes I'd probably replace 'em either way.
No problem running new lifters on an old cam btw, you just can't do things the other way around.
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The lifters and the cam wear together big time. If you mix up your lifters chances are you're going to toast your cam in pretty short order. Essentially the cam lobes get a bit of a dish to them that matches the specific lifter it was running on.
I read somewere that vw cams are made much harder than American cams.
What about mechanical heads where you gotta change the shims from time to time? AFAIK most people reuse the shims too ;D.
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The lifters and the cam wear together big time. If you mix up your lifters chances are you're going to toast your cam in pretty short order. Essentially the cam lobes get a bit of a dish to them that matches the specific lifter it was running on.
I read somewere that vw cams are made much harder than American cams.
What about mechanical heads where you gotta change the shims from time to time? AFAIK most people reuse the shims too ;D.
VW cams are way harder alloy, i read that a few different places.
and you only have to keep lifters matched to lobes when they are worn together. you can take an old can and wear new lifters to it, but you cant take a new cam and wear old lifters to it. is what i see people do lots of times, is turn the adjuster shim over when installing a new cam, or when using it on a different cam.
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Last weekend i cleaned up the block and painted it CAT Yellow. Deglazed the cylinder walls, Bearings and rings ordered.
Crappy iphone camera, my good one was in the house.
(http://img.photobucket.com/albums/v393/kaneb/photo-1.jpg)
I picked up the bearings and rings. Bearings are manufactured by kobleschmit and the rings by cofap. I'm pleased as i wanted well made bearings and rings and from my research these seem pretty good. Just doing some wiring today in the engine bay and behind the dash. Satuday ill put together the bottom end. Im pretty happy about the progression right on my time line.
My updates to come after the weekend.
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Clutch question. I was going to go with a eurospec lightened flywheel, 16v pressure plate and an 8v clutch disc. Problem is i wont be able to get the flywheel till spring. So i am stumped for a flywheel. How would a stock 8v flywheel do??
Kane
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I know you wouldn\t want to suck too much water in but wouldn't a little mist act some what like water/meth injection? I believe I read a post here sometime ago about more power in humid damp weather so maybe a air filter in the rain tray will become the new chemical intercooling ;D
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Clutch question. I was going to go with a eurospec lightened flywheel, 16v pressure plate and an 8v clutch disc. Problem is i wont be able to get the flywheel till spring. So i am stumped for a flywheel. How would a stock 8v flywheel do??
Kane
i prefer the gasser flywheel, its just like lightening the stock one. but most of them dont have the TDC mark, make sure yours does before you put it on, or scribe a mark where its supposed to go.
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I see. Well im picking up my HG and timing belt/tensioner today so ill see if i can get my clutch ordered up as well.
Yeah i have read that about the timing mark. when using the gasser clutches with the diesel.
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I see. Well im picking up my HG and timing belt/tensioner today so ill see if i can get my clutch ordered up as well.
Yeah i have read that about the timing mark. when using the gasser clutches with the diesel.
when/if you decide to go with the gasser flywheel, just ask me and ill take some pics of where i had to put my TDC mark.
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Awesome thank you kindly sir!
Your running 2.5" piping for your intercooler I see in sig. I have some 2.5" laying around. Mazda ic wouldn't fit to good so picked up a stock 1.8t ic. I was worried about lag with the bigger diameter piping. Do you have any issues with your set up?
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nah, im running 2 1/2" exhaust. the piping from the intercooler to the turbo is around 1 3/4" or so, then from the intercooler to the engine it is around 2 1/2" or so rubber billows hose.
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gotcha,
Little update. Measured my piston protrusion, i know it's not a real straight edge but worked. Same notch as old HG so i bought 1.9 metal HG. Bought the timing belt/tensioner and ordered the clutch. Then last night. I pulled the head all apart again. Was going to replace the valve seal's but after replacing one without proper tools i figured it was more of headache then it was worth, seals look fine and i did a leak down test once it was back together with no issues. I didn't like how the paint came out so i stripped it as well. Threw it in the hottsie at work to clean it after i did some polishing of the ports. Installed the oil pump and arp head studs. Need to go back to the shop and throw in some other parts in the hottsie, wire wheel and paint them. I want to have the engine together before i pull the old engine to work on the engine bay. Less dust to get into it as it will be sealed up. And also less clutter in the garage.
Onto some pics-
(http://img.photobucket.com/albums/v393/kaneb/DSC_0140.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0128.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0139.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0135.jpg)
As you can see i used the shops spring compressor a little big put a cut a little pipe down and made it work. (http://img.photobucket.com/albums/v393/kaneb/photo-4.jpg)
1.8T Intercooler, Mazda one wouldn't fit as i wanted it to.
(http://img.photobucket.com/albums/v393/kaneb/DSC_0137.jpg)
If it was warmer or my garage insulated i would be there working on this not here posting but oh well. Still on a decent timeline for it.
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Well i've got a bit done to this little sucka. Last week i pulled the old engine. Robbed it of the parts i needed like the mk1 injector pump bracket/engine mount. I picked up some new engine mounts at c1 and then pressed them in at work. Also cleaned up the ip and did the governor mod on it. I wasn't going to but figured well it's out and clean may as well. Lately i've just been doing a lot of cleaning, prepping, polishing and painting. I'll be into that engine bay quite soon.
The engine is really shaping up quite nicely. I'm looking forward to once it's in the car.
(http://img.photobucket.com/albums/v393/kaneb/DSC_0171.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0172.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0181.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0182.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0184.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0185.jpg)
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I love the paint job. It looks really great with all the bits painted a dark color to contrast with the block. Nice job!
Polish on the intake looks good too.
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damn, that's looking mighty fine!
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Thanks guys.
Question- Fuel line for the ip, i wanna run all new clear lines. Whats the id of it? I thought i read around 7mm am i way off? Would like to pick some up soon. TIA!!
(http://lh3.ggpht.com/_I-V8YHCsxZA/S3cPDoyBA1I/AAAAAAAAAl8/5reb_RKk2TI/Caterpillar-logo.jpg)
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I do heavy diesel mechanics for a living all hwy rig's. So the piping is made up of air to air piping and such. It may be over the top but thats the plan for the car. It's a wannabe truck... hence going with a cat theme. The big intake is fun. Probably move it to the rain tray as i want to run my intercooler piping where the intake is.
Is there good air flow in the rain tray? I would think it would be cooler there since it's more isolated from the engine bay, Thoughts?
My first engine was CAT yellow ::)
(http://img.photobucket.com/albums/v648/stewardc/Truck/100_3045.jpg)
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FUEL SUPPLY & RETURN 7MM
IP IS 1.5 MM
GB
I have plenty of VW cloth braid 2.5 & 7 mm in stock if you need some ??
BATTERY CABLES SHOULD BE 1/0 GAUGE ( POSITIVE )
2 GAUGE NEGATIVE
I HAVE SOME NEW ONES IN THE SALE SECTION...
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wow, this is a nice build indeed - really like the colour scheme!
can i suggest a few things about cams a lifters? there was a lot of "interesting" information on the last couple of pages, I thought I would clear it up.
> First - yes, as someone mentioned, you should keep the lifters in the same order because of the lifter BORE wear (and, if solid, the shim thicknesses obviously).
> Cam lobes are always ground at a slight angle, and this is for a reason - it is so that the lifters always rotate in their bores during normal operation. as the cam presses on the lifter, the centre of contact is slightly off centre with the line of the lifter bore and this causes the lifter to rotate slightly.
> shims and hydraulic lifter tops are EXTREMELY hard material and will not, over extended time, appreciably wear during normal use. If something fails (the lifter stops roatating in the bore, for instance) wear will occur (due to overheating of the friction surface)
> you may never turn over a shim, since they are marked for thickness (it is etched) on the "bottom" and this will cause wear over time due to roughness
> lifters dont "wear in" to cam lobes. they will wear into their bores however... or rather, they will wear in the bores to themselves (the bore is much softer than the lifter.
HTH :-)
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Thanks guys.
Gee-bee- Thanks, I picked up some fuel line this past weekend. I also relocated my battery into the back, I used 2 ot cable as i got some extra from work. A little over the top but hey better to big then to small.
For the lifters i am not sure the order as i mixed them up, my big "doh" experience in the build. I plan on a new head,lifters and cam. Well not new but new to me. The head has some cracking starting at the pre-chambers. Might even look into the 1.9 head. I'm hoping it runs fine haha.
Engine is getting timed thurs. Bay cleaned up this weekend. Im hoping to have it running in 2-4 weeks. Still need to get my DP made. I made a manual boost controller up.
Im getting stoked.
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what are you doing for a downpipe? I'm planning on ordering some 2.5" mandrel U bends in the near future if you want in.
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I have some 2.5" pipe im going to take to carline and get bent up and just make my own flange. Well thats the plan so far.
But thanks, otherwise i would be in for sure.
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Progress...Thought id update as i left my keys in my garage last night and am locked out now on my day off.
Got a bit done, Took my injectors to gcl and got them re-done. Getting pretty close to driving again which will be nice.
Before--
(http://img.photobucket.com/albums/v393/kaneb/photo-7.jpg) (http://smg.photobucket.com/albums/v393/kaneb/?action=view¤t=photo-7.jpg)
After--
(http://img.photobucket.com/albums/v393/kaneb/DSC_0199.jpg) (http://smg.photobucket.com/albums/v393/kaneb/?action=view¤t=DSC_0199.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0198.jpg) (http://smg.photobucket.com/albums/v393/kaneb/?action=view¤t=DSC_0198.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0200.jpg) (http://smg.photobucket.com/albums/v393/kaneb/?action=view¤t=DSC_0200.jpg)
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I will have the stock 1.6TD & aaz intake duct available in silicone in two weeks
black , red, blue
Includes silicone s/s clamps
27.50 shipped
let me know
GB
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Ready to start had some issues. Engine was cranking really slow so i cleaned up my grounds really good and it's cranking over much better. Another issue is getting it primed up, I tried using a vac gun off my air compressor on the return line of the ip while cranking and i can't get all the air out cause my vac gun can't keep up. Also my glow plugs aren't lighting up. I have power at my relay when key is on, i brought home a multi-meter tonight. Weird thing is when i flick my hight beam switch, it's like it back feeds and puts on the gp's diode in the dash.
Edit- Re-checked ip timing. It's set right on 1.00.
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Car's running found i had a leak at my rear main thursday night so i pulled the tranny right away, replaced seal and gasket put back together and was driving it yesturday afternoon, runs good. I find though it's abit smokey on start up but runs really good once it's warm. New engine is better then the turbo na, way more power. Boost and fuel set at stock settings for break in. Sounds kinda neat to with the intake in the rain tray when you hit boost.
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Car's running found i had a leak at my rear main thursday night so i pulled the tranny right away, replaced seal and gasket put back together and was driving it yesturday afternoon, runs good. I find though it's abit smokey on start up but runs really good once it's warm. New engine is better then the turbo na, way more power. Boost and fuel set at stock settings for break in. Sounds kinda neat to with the intake in the rain tray when you hit boost.
i told everyone that the intake in the raintray is the cats meow. you are the only other one besides me running a rain tray intake that i know of atleast.
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lookin good. what color paint is that?
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the cat's meow LOL so cute :-*
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Engine's cat yellow and car is a cream i think it's called sante fa tan or something.
Car is excessive smokey on start up idles rough. Idle smoothes out when cold start advance is pulled out. Engine runs like a top when warm,smooth, and no more smoke either. Maybe need to check pump adjustment again?? It was dead on 1.00.
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nothing wrong with a little advance.
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Haven't had to many issues. Coolant gauge in car isn't working as i check the temp with a laser gun and its at 160. So i have to track that down. Cluster lights aren't working either so i have to figure that out. Curious if they share a common ground? But everything else works in cluster(clock,fuel gauge and all the diode lights). I believe the sensors for coolant have been working fine because my glow plugs work without an issue.
Fixed my oil leak at the dipstick, vw had no parts for it in north america so i got the specs from vw of the o-ring and washer size and i actually got a Cat o-ring from work to work. Once thing i have noticed is i have a lot of pressure coming from my blow by out of the valve cover. Not a lot of oil(maybe a couple drops i can see that has dripped onto tranny). I had my 120 degree spacing in my rings on install. Engine runs good and smooth. I haven't been able to monitor the oil consumption since i just fixed the dipstick oil leak not to long ago but will. Maybe just needs a bit more breaking in?
Thinking of installing the intercooler in a few weeks.
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Here's what it's looking like. IC and downpipe to come soon.
(http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs543.ash1/31763_391725917340_506177340_4631172_7829310_n.jpg)
(http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs633.snc3/31763_391725932340_506177340_4631174_6724016_n.jpg)
(http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs543.ash1/31763_391725947340_506177340_4631175_4954246_n.jpg)
(http://sphotos.ak.fbcdn.net/hphotos-ak-ash1/hs543.ash1/31763_391725962340_506177340_4631178_4155096_n.jpg)
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wow!
motor looks amazing, nice work!
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Whatta wabbit
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freakin clean dude :o
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Well i did some work on my little beast this past weekend.
Made a new downpipe. Free and non-leaky so thats good. Noticed my egt's went down on hard pulls ups hills. Turbo sprools up faster. No more turbo sigh when i'm off throttle :( i liked the little phaser sound haha. Didn't have a mig so braz welds hopefully hold up.
(http://img.photobucket.com/albums/v393/kaneb/37ce3588.jpg)
Installed
(http://img.photobucket.com/albums/v393/kaneb/DSC_0056-2.jpg)
Engine bay/car
(http://img.photobucket.com/albums/v393/kaneb/DSC_0061-1.jpg)
Like my boost controller??
(http://img.photobucket.com/albums/v393/kaneb/DSC_0062.jpg)
Fog lights working
(http://img.photobucket.com/albums/v393/kaneb/DSC_0050.jpg)
Still need to hunt another intercooler. The mazda 626 one doesn't fit right as there one port points right at my alt. The 1.8t IC doesn't fit right either. I want to run my pipes in between the timing belt and the fuel filter. I would love to find a longer narrow ic with both ports on the same end. I have some parts hunting to do i guess.
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Thought of going the Air-Water route for the IC? Way easier to fit in there... That'll be my next purchase after the ccard is paid off!
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Thought of going the Air-Water route for the IC? Way easier to fit in there... That'll be my next purchase after the ccard is paid off!
How would one do that? You can go quite smaller but still effective right? Now you got me thinking.
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You get a kit, like one of these:
http://www.votionspeed.com/servlet/the-Water-to-Air-Intercooler-Kits/Categories (http://www.votionspeed.com/servlet/the-Water-to-Air-Intercooler-Kits/Categories)
For piping all you need to do is a loop in your engine bay, probably not more than a couple of feet total. Less lag that way! There's a small radiator that you can stick just about anywhere since it's got its own fan. My car has no A/C so there's enough room to squeeze it in front of the main rad, but there's a few other places that'd fit too. Works exactly the same way as the cooling system in the car - you've got a pump circulating coolant from the intercooler through a radiator.
I'm probably just going to use something small for a reservoir - a washer fluid tank or something like that. Saw someone on here that just used a foot long section of 4" ABS pipe with caps on either end - that'd work great too! No need for anything huge unless you spend a LOT of your time at full boost, water can absorb a tremendous amount of heat.
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is that new down pipe mandrel bent?
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please do your turbo a favor and get rid of those bolts holding your down pipe on. buy some studs, nuts and washers. i have better luck with studs in a turbo than bolts.. you will be thanking yourself later, trust me.
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I have a new turbo for it that has studs so i'll go that route in the future for sure! But for now its just some bolts with some anti-seize on them.
Anybody have experience with thin rad fans? Anything from other manufactures i could pick up from the wreckers and put on and get rid of the stock shroud and fan? Trying to clean it up and i have to move my rad to fit in my IC and the stock fan and shroud are just in the way and bulky, i suppose i could do some hacking but would rather something with a nice clean look. Also i'd like to mount the fan in front of the rad as well.
Thanks!!
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Same thought here, I was thinking on installing a 16V scirocco radiator 675 mm long, but it would be close to the alt
Then I would have to spend the bucks for a twin thin fan assy ...
Gb
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GEE-BEE, i found two great fans at the junk yard off a Taurus that work REALLY well! I only actually need the bigger of the two! I made my own bracket out of some 1/8th x 1 inch steel flat bars drilled some mounting holes and off i went.
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I got a 10" push fan for the front yesterday bought new. I'm going to install it right now here. Should be perfect.
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What i've been up to lately with this thing,
(http://img.photobucket.com/albums/v393/kaneb/photo-30-1.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0205.jpg)
(http://img.photobucket.com/albums/v393/kaneb/photo-33.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0203.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0003-3.jpg)
(http://img.photobucket.com/albums/v393/kaneb/DSC_0007-2.jpg)
Still have lots of work to do before spring. Been having rear main seal issues :-[ :-[ :-[
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Nice work man.
What's the story on the can at the top? I assume it's an oil catch can?
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New IC pipes installed and are great, making 18psi of boost right now. Catch can not installed need a couple tweeks on it. Will get pics of all that once i get the bay cleaned up, been working some crazy hours.
Friday night i hit a bad bump, pretty much a speed bump in the road and the pan touched down pretty damn hard. Squashed it a good 3/8 of a inch. Plated a new pan, it's a much nicer pan then the old one.
New- (Used the new mig at work:thumbup:)
(http://img.photobucket.com/albums/v393/kaneb/photo-36-1.jpg)
Old- After welding front piece on a yr. ago(Arc welded and real ugly)
(http://img.photobucket.com/albums/v393/kaneb/photo-35.jpg)
How it looks right now.
(http://farm6.static.flickr.com/5103/5678402602_8735e55da9_z.jpg)
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Car is amazing! Awesome man.
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Got any more (bigger) current pics of the car? Sweet build :)
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More updates pleeeze.
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You've got one of my favourite Rabbits of all time. Is that beige a VW colour?
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I love the graphics.
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No it isn't a vw color unfortanetly. It will get proper paint once i get to doing some body work.
Thanks the graphics are actually painted on, they came out pretty good!
Cleaned it up and snapped a few pics. Need to detail the bay still. It's been running like a top!
(http://farm4.static.flickr.com/3269/5875481776_9972ddc06d_b.jpg)
(http://farm6.static.flickr.com/5111/5874925833_b4108b660c_b.jpg)
(http://farm4.static.flickr.com/3045/5874916769_d390c027f5_b.jpg)
(http://farm6.static.flickr.com/5188/5874936135_a25544673e_b.jpg)
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I love this thing Kane! Good to hear it's running like a top ;)
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Well i thought i would post an update since spring is springing onto us ;D. This is how it went away last year.
New slippers for the ol boy.
(http://farm8.staticflickr.com/7239/7203860652_39bb8e0575_z.jpg)
Ventured into more shine under the hood.
(http://farm8.staticflickr.com/7242/7290165286_69399fe06a_z.jpg)
How it currently looks.
(http://farm9.staticflickr.com/8464/8080640294_f4b9c7502b.jpg)
I have picked up a new intercooler that will have much better flow then the mazda 626 IC. I scored the intercooler while picking up other parts for the car. It's either renault or peugot(sp?). It has bigger openings and is thicker and i can mount it on the pass. side instead of drivers. I think the mazda one was fairly inefficient. Car ran decent last year, have some bugs i'd like to work out this year. Was going to do full restore but plan on not spending the money on it this yr. Some rust repair and that is it. I also picked up a early style rad that has the overflow built into it. I know the diesel one is bigger but the previous owner put one in the same size as the early. I'll be glad to remove the overflow bottle and unnecessary lines. I plan on polishing a couple more things to for ***s and giggles.
I'll keep ya posted--Kane
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You might consider a bar from frame to frame that is in front of and slightly lower than the pan rather than making the pan the low point that gets hammered on.
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Here's a short clip from last year. My dad took a short clip after seeing it for the first time in person as he lives across the country.
http://www.youtube.com/watch?v=VCv_E7RhlzU&feature=share&list=FLWTILvY_zT2RaCcPWs81i-A (http://www.youtube.com/watch?v=VCv_E7RhlzU&feature=share&list=FLWTILvY_zT2RaCcPWs81i-A)
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What's your exhaust setup on that? It sounds good.
Sent from Outer Space!
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Thanks! 2.5" turbo back and a nice big intake on it too.
libbydiesel- I get what your saying probably wouldn't be a bad idea. I'm pondering about either raising the engine a touch or shortening the pan and p.u tube. Then adding a external oil cooler so i use the same amount of oil. But last year i had no issues minor bumps and scrapes on the pan. Car is a wee bit higher with the new wheels.
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Alot of great work in this beast! I actually found your video on youtube a long time ago and it's what made me kind of excited about my 1.6D. Is your 2.5" just a straight pipe or do you have any resonators/mufflers? You should definitely add this to the official exhaust note thread =http://www.vwdiesel.net/forum/index.php?topic=33076.0 (http://=http://www.vwdiesel.net/forum/index.php?topic=33076.0)
This is probably my favorite sounding 1.6td ever.
Also what's the specs on your new slippers? 15x8 195s?
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Thank you Rising! I just added it to that thread. Yep just 2.5" turbo back no mufflers or resonators...Give it that tractor sound haha. The wheels are 15X8 axis og sans. ET25. The rubber bands on them are 165/45/15's less rolling resistance with skinny tires right? haha. Once i have it running again i'll try and get another video on youtube or something!
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Well that's certainly an easy sound to acheive haha. How is it at cruise? does it drone much at all? And what about the tone in person? I know mine sounds miserably tinny when I rev it up. But i'm running a stock exhaust. So thats pretty much why. But I'm really hoping when I install this turbo and run my exhaust the tinny goes away :) Else I may have to install a decent resonator to take off the rasp.
Where'd you find 165s?!! I just bought a set of tires for my 15x7's but all the 165s were out of stock everywhere. and I couldn't find a decent deal on anything smaller than a 195. But I got my 195-50 ziex 912's for 206 shipped all corners.
Anyway it's a good look. Next set I buy I'm going to stretch some if I can find any. . .
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Damn it, i used to run 13X8 until the tires were impossible to find. Hopefully they keep making the 165's for 15's maybe we will see them pop up again come summer.
Car isn't too bad cruising i've heard and been in much louder cars. The turbo keeps it quiet. Only time i find it's louder is when the windows down and i'm hot doggin the go pedal while accelerating like in the video. Sound is deep for a 1.6l for sure. And at idle the turbo spool is awesome, it really whistles driving through parking lots. It gets some looks like wtf is in that car to people unfamiliar with them ha.
Before i did the TD engine the car was NA and it was not as much fun. I through the turbo bits of the current TD onto the NA while i was rebuilding it. Had alot of fun, way more go. The turbo will awake the beast in the 1.6L believe me.
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yeah let me know if you find any around for a decent deal. Maybe if we keep buying them demand will keep them in business!
Yeah man it seems lime a great sound. And I'm fairly certain my vnt is supposed to spool ridiculously fast once I get the control method hooked up. So I'm sure that'll sound pretty wicked cruising around parking lots haha.
Everyone makes these magical turbo devices sound so wonderful... I really need to get on that. Maybe I'll post up soon and see of I can get some of my problems worked out to get this thing running. I have a TD block and head... just not all the bits....
Sent from my ThunderBolt using Tapatalk 2
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Little update. Still love this car!!
New intercooler installed this year out of a i believe a renault.
(http://farm8.staticflickr.com/7390/9260796155_870597fb5b_z.jpg)
(http://farm9.staticflickr.com/8139/8704256809_9f35e0642c_z.jpg)
Fab'd up a new exhaust tip as i couldn't stand all the soot on the back of the car.
(http://farm9.staticflickr.com/8403/8997578997_1ab677a71e.jpg)
We're the 3 best friends.
(http://farm9.staticflickr.com/8272/8704256511_c3096cef66_z.jpg)
Was able to fit all 3 cars in my double garage yesterday.
(http://farm8.staticflickr.com/7307/10635773735_3ae15c9b2b_c.jpg)
(http://farm3.staticflickr.com/2890/10648984605_249edce901_c.jpg)
This also happened too. (rabbit burn out/roaling coal content)
http://youtu.be/dQQ1R9YpKoM (http://youtu.be/dQQ1R9YpKoM)
http://www.youtube.com/watch?v=OrRaOxog1Ko (http://www.youtube.com/watch?v=OrRaOxog1Ko)
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I agree with the statement at the end of the video. What happens when block of wood releases and car goes into garage not out?
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(http://farm9.staticflickr.com/8272/8704256511_c3096cef66_z.jpg)
Oh COOL, our new turbos came in. Which one is mine and which is yours ????
::)
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I agree with the statement at the end of the video. What happens when block of wood releases and car goes into garage not out?
Oh i agree it was pretty dumb. Wheels were chocked on both sides, park brake on, and i oil'd the front front tires. What can i say i like living on the dangerous side.
Stewardc- hahaha take your pick!
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;D ;D ;D ;D 8)