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Engine Specific Info and Questions => TDI Engine -General Info => Topic started by: fuslit on August 05, 2010, 12:16:06 pm
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Hello everyone,
Thought I'd post up a project I'm putting together: (I re-assessed priorities and have dumped my gtd rabbit project and focused on this instead, it frees up space in my garage too!)
Anyway, my daily driver is a 98 tdi jetta with some pretty bad rust issues in the gas tank and trunk area but drive train is decent. It's got 193k plus or minus a bit, I did the timing belt, tensioner rollers at 180k water pump not long after... (should have done it at the same time... oops) put new glow plugs in, new glow plug harness and a few other maintenance items I'm forgetting off the top of my head.
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100610_rims/PIC-0175_640.jpg)
The current mods:
- stage 2 chip from malone tuning http://malonetuning.com/?page_id=62 (http://malonetuning.com/?page_id=62)
- downpipe back straight pipe (my exhaust rusted out, this was the cheap replacement for the moment)
- larger injectors (Sprint 764)
- boost gauge
current problem:
At the moment I have a random (not repeatable) intermittent boost issue I haven't been able to pinpoint. I believe is associated with my turbo's waste gate sticking (when I bought it it was frozen up, I managed to free things up with pb-blaster and some vise grips and moving things around, it's not exactly an easy spot to reach.) but my n75 valve could also be part of the problem. While I'm doing the swap I will pinpoint where things are freaking out.
After looking at the body work that I'd need to do and by chance my buddy was parting out his turbo vr6 jetta which lined up a pretty much rust free glx. Based on the cost of bodywork, and upgrades that the glx would have I worked out a price with him and I'm buying his shell for the swap.
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100730glx_shell/PIC-0246_640.jpg)
Things the glx shell has on it: (and should come with, going to be picking this up friday)
- clean title / fresh paint
- no motor/trans/radiator
- no engine wiring/ECU/cluster
- no emissions stuff
- will have shifter box and hydraulic clutch stuff.
- stock 5x100 15" wheels, stock suspension. will have axles.
- will have 11.3" brakes / rear disk with newer MK4 calipers. stainless lines. ebrake holds.
- control arm: polly bushings in front. R32 rear
- no seats; will have black door panels. black dash. black carpet.
- neuspeed upper tie bar.
- neuspeed front and rear lower sways
- 2.5" TT stainless borla exhaust with TT test pipe
- stock headlights
Things the shell needs fixed:
- passenger fender kinked. front/rear bumper needs paint.
- bad steering rack (i dont think yours will work). pressure line also needs replacing (your line should be fine)
- no seats, door cards will be swapped over with a k2 jetta door card. (I'll be swapping in my seats which are from a 95 glx)
Things I'll swap over from my current tdi:
- Suspension from my current tdi (noname cupkit)
- motor & transmission
- engine bay wiring harness
- gas tank
Things I have ordered or am building or have on hand for this swap for upgrade/replacement:
- Stuff to make a stainless downpipe
- ebay cxracing fmic from ebay
- new motor mounts (g60 solid transmission mount, oem front and rear engine mounts)
- new strut bushings
- aircraft spruce egt probe (plan on connecting a vdo gauge I have hopefully it's the correct type)
- manual boost controllers (I'm picking up two of these to use until I get things dialed in)
Fabrication:
- short shifter (a friend of mine makes these, I'm getting a decent price on it so I'll try it out)
- the downpipe
- custom 3 gauge holder thinking about a green sand casting of one I have now but it needs some work.
- building a custom intake from a volvo d24 (egr delete) ported and polished
a couple images of that so far (I've beadblasted it and my buddy will tig-weld it for me)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100731_beadblasted_intake/IMG_1802_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100731_beadblasted_intake/IMG_1813_640.JPG)
- k24 turbo from an audi 5000 diesel (will custom exhaust adaptor & or manifold adaptation to make things work correctly)
(http://www.fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/01-27-07_turbo/Audi5-cyl3_640.jpg)
The info I've pulled from it shows that it's a k24 from a 2.0L audi turbo diesel seems to be in decent shape. I'm thinking about pushing in the range of 20-25psi (I would like some input on this particular turbo, has anyone here run them on a tdi? also sorry for stupid questions, I haven't found any maps on it and am still learning about turbos.)
http://www.turbo-product.com/KKK/K24.ASP (http://www.turbo-product.com/KKK/K24.ASP)
model # I found 069145703 shows the following
Turbocharger - KKK
Mark - Audi
Model - 100 TD
Year - 1981-01
Engine - 720/5 (2.0)
H.p. - 87 D
Family Turbo - K24
Turbo Code - 53249706081
O.E.M Turbo Code - 069145703 3K (maybe this is the max rpm?)
Things that will need to happen once swap is complete:
- paint bumpers and one small ding
- Once things are up, running (and most importantly stable) I will look into an upgraded 3 bar MAP then get another custom tune from malone for some more power.
- Find out what it would take to get the MAF working (using a vr6 cluster mod the tachometer I've read a bit about it but it's on the back burner at the moment)
The goal of this project is to have a decent reliable daily driver that has enough power to pass when I need to, and have a fairly good mpg. my commute is about an hour one way so most important is it needs to be reliable. That said, the glx will have tons of upgrades that my current one lacks, an interior for instance because I have a huge rust hole in the trunk area that is letting water in...
Anyway, thanks for reading (and stay tuned) I am gonna try and wrap this up by September! (a lofty goal for me)
-Todd
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Looks and sounds like a cool project.
I had a K24 on an e-tdi in my syncro. It boosted just fine with very little noticeable lag. I think you'll find it works fine in your application as the Jetta will be lighter than the B3V Syncro.
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Looks and sounds like a cool project.
I had a K24 on an e-tdi in my syncro. It boosted just fine with very little noticeable lag. I think you'll find it works fine in your application as the Jetta will be lighter than the B3V Syncro.
Cool, Thanks for the feedback, The one thing I've had a little trouble finding is the efficiency envelope for this turbo. Tow much boost were you running in your syncro?
-Todd
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Just replaced the n75 valve and took it for a spin.
Started out, hit 3rd gear 2500 rpm and hammered it, The new N75 valve and holds it at 15psi!!!
While I only went for a small drive, since the gauge didn't get above 15psi I'm 99% sure my intermittent boost issue is fixed!!! (except now I want more boost...)
This is so Awesome to nailed the cause of this before I did my swap (of course everything I had read on this subject pointed at a bad n75, although I think it was a combination sticky n75 valve and frozen waste gate)
I guess next time I'll not be so such cheap... *grin*
-T
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I got the car delivered yesterday to the shop things will be taking place, have a lot of work ahead of me which I need to get cracking on to make headway, gonna try and spend some time on it today, but need to do rear shocks in my wife's mk4 golf tdi before I can get over to that one.
At this point I'm leaning towards buying a new (well rebuilt) steering rack, the guy I got the car from hasn't had a chance to pull a used one and I don't want to have that hold up the swap.
I'll try and upload some better res images of the shell.
-T
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Yesterday I got the dash out of the glx, which should make the fuse block re-wire go much much faster.
Also got my short shifter installed.
Next step is removing the steering rack so I can figure out what direction I'm going to go with that. Once that is replaced, the car should be ready for the swap, I'm just waiting for the parts to show up. I guess I could start taking a look at egt probe placement on the exhaust manifold.
before
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100807_dash_removal/IMG_1805_640.JPG)
after
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100807_dash_removal/IMG_1810_640.JPG)
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While the dash is out I'm contemplating replacing the heater core, clean the evaporator unit for the ac, and replace the foam (to reduce flying dash bits)... not sure yet if I want to tackle yet, but it would give me something to do while I wait for parts.
Anyway, Got the rear door panels off and ready to have the new ones swapped in.
and these showed up today (cool.)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100809_tri_brackets/IMG_1810_640.JPG)
They'll be used for the downpipe, was hoping that I could use one as an interface with the turbo, and one to match up with the exhaust that's on the shell currently.
looks like it'll take some custom fabrication to work, but the price of a stainless flange that I found was twice what two of these cost!?! I figured I'd try this out first it's not 'that' far out of line I think I'll be able to get it to work fairly easily. (still need to go over to see if they'll fit the exhaust bracket that's on the car now.)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100809_tri_brackets/IMG_1813_640.JPG)
I think pretty impressive for what they cost, makes me sad that I can buy these on ebay so cheap and have stores that are 'reputable' sell the same (most likely as almost nothing is manufactured in the US anymore) thing at 2-3x the markup... but that's a story for another time :)
Also, the steering rack is ordered and should be here in a couple days.
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Looks and sounds like a cool project.
I had a K24 on an e-tdi in my syncro. It boosted just fine with very little noticeable lag. I think you'll find it works fine in your application as the Jetta will be lighter than the B3V Syncro.
Cool, Thanks for the feedback, The one thing I've had a little trouble finding is the efficiency envelope for this turbo. Tow much boost were you running in your syncro?
-Todd
No worries. I don't have the car any longer and it didn't have a boost gauge nor a EGT so I can't answer those questions, sorry. I think the ECM had the standard chip although I don't recall that detail. But driving it with the K24 was similar to the K03 in terms of when boost came on maybe it was a couple/few hundred higher but with the factory syncro gearing the car had better than stock performance.
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No worries. I don't have the car any longer and it didn't have a boost gauge nor a EGT so I can't answer those questions, sorry. I think the ECM had the standard chip although I don't recall that detail. But driving it with the K24 was similar to the K03 in terms of when boost came on maybe it was a couple/few hundred higher but with the factory syncro gearing the car had better than stock performance.
Thanks for the info, that helps give me an idea of how this turbo will perform.
I found a good price on a heater core ($23.61) [http://www.autohausaz.com/] so I went ahead and ordered it along with new fluids (vw power steering and g12) that I covers most of what I'm looking to do here. (Hopefully)
So, Other than title/registration and cost of materials to finish the exhaust and intake (misc silicone couplers, cost of a refill on a bottle of argon) and final paint work I hope (crosses fingers) all costs are taken into account.
I'll make some progress on this tonight.
-T
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More parts have arrived :)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100811_intake_intercooler/IMG_1801_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100811_intake_intercooler/IMG_1804_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100811_intake_intercooler/IMG_1805_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100811_intake_intercooler/IMG_1810_640.JPG)
how the 90 degree bend lines up
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100811_heater_core/IMG_1809_640.JPG)
well this was a pain but the heater core's out. Can't imagine what it would be like to try and get to this with the engine in the way... even more of a pain!
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100811_heater_core/IMG_1801_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100811_heater_core/IMG_1802_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100811_heater_core/IMG_1805_640.JPG)
The new heater core won't be here until next tues ... but honestly there's alot of things that need to happen between now and then.
-Todd
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Last part of the downpipe showed up today,
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100812_steering_rack/IMG_1801_640.JPG)
and the steering rack showed up... but... i think it's the wrong one. (need to do a little research, the invoice says for a vr6 corrado)
anyway, pics of the removal/comparison.
old rack (pay attention to the three bolt holes on top)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100812_steering_rack/IMG_1803_640.JPG)
out:
the new rack appears wider, the bolt holes are missing. I didn't bother to measure, i'll confirm the part # I need then chat w/guy I bought it from.
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100812_steering_rack/IMG_1809_640.JPG)
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So, I just heard back from the place I got the rack. The owner checked with their supplier who says that they've never had any problems with these, says the intended application is vr6 mk3 jetta. He usually knows what he's talking about and would not intentionally jerk me around, So I'll give it a shot.
Basically I just wanted to confirm that it if I had to return it (i.e. it doesn't fit that it won't be a problem.)
This weekend I'm going to try and catch up with my buddy who's gonna help out with the tig welding to weld up the intake.
-T
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So,
I ordered a bunch of stuff through arizona autohaus which showed up yesterday, some of the parts I ordered (brand of Meyle) came with stickers saying made in china... I just wasn't expecting that.
I guess the US isn't the only place that outsources to China it will be interesting to see how they hold up.
I'll be attempting putting the steering rack in the car today, hopefully it works as the supplier claims it will. We'll see how that goes.
-T
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Got the intake trimmed down and have a plate cut out for welding. (may have to trim it down a bit, but wanted to make sure I had enough so I didn't have to cut another one.
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100814_intake/IMG_1801_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100814_intake/IMG_1803_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100814_intake/IMG_1808_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100814_intake/IMG_1813_640.JPG)
now to go put the steering rack in...
-Todd
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Steering Rack is in (this is taken 1/2way through without all the nuts being tightened down)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100814_steering_rack/IMG_1818_640.JPG)
next step is focusing on the interior (door cards, wiring harness & fuseblock) as well as motor mounts and suspension bits.
-Todd
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The heater core, coolant and power steering fluid showed up today and started putting wiring back in the fuse block
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100817_fuse_block/IMG_1801_640.JPG)
Chatted with the guy who's helping me fabricate the intake and downpipe and ordered a couple more silicone bits that are going to be needed to make the intake tubing work with things. I did chat with another friend about trying to find a reducer pipe instead of a reducer coupler, but in terms of 'quickness' I opted to go with two couplers, one for the intake of the turbo (2.5" -> 2.25") and one for the inlet of the intake manifold (2" -> 3") the outlet of the turbo is 2" and the silicone couplers that came with the intercooler kit fit right on, so I lucked out there.
I need to figure out the oil supply/drain lines for the turbo as well, I might be able to use the turbo diesel oil supply line that I have (we'll see) Going to need a custom drain line for for the turbo I think.
I'm attempting to line things up to get this swap stated/finished this weekend (we'll see how that goes fingers crossed.)
-T
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Caught up with the guy who's been helping out with this project tonight, he started tig weldeing on the end cap! A huge thanks to him for helping me out on this project! I really really appreciate it.
in progress shot :)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100818_intake/PIC-0294_640.jpg)
I only have crappy cell phone pics of how it is turning out, this is the best one I got but I think it's going to be pretty nice all said and done..
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100818_intake/PIC-0297_640.jpg)
Also worked on figuring out what needs to happen next to mock up the turbo to figure out how things will sit (with the intake) as well as oil drain lines, so I'll work on that tomorrow.
but I'm beat, have been up since 4 am so right now I'm going to bed.
-T
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Started the swap (for real there won't be many pictures as my camera's battery died and I need to figure out where the charger is.)
So, started mocking things up, the 1.6 td intake will not work with the d64 manifold.
so, I took the adapter plate I had, and adapted it for the tdi exhaust manifold
Basically milled out spots for studs to be welded in and had a neighbor who welds much better than I can weld them in.
This is a prototype... probably won't work... we shall see.
crappy cell pics before welding:
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100819_turbo_adaptor_plate/PIC-0298_640.jpg)
I didn't take any of it finished. but, here's one mostly finished.
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100819_turbo_adaptor_plate/PIC-0300_640.jpg)
Also pulled, the dash last night so that's out and I'm trying to guesstimate what I can get done today.
-T
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egr blockoff & turbo drain flanges are made.
quick cell pic
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100820_blockoff_plates/PIC-0304_640.jpg)
lunch and then back at it.
-T
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I managed to get alot done today the biggest milestone, the motor is out!
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100821_motor_out/PIC-0306_640.jpg)
Also, I got a majority of the harness labeled, I will pull the engine bay harness tomorrow and work on getting things moved around to get ready to put the motor into the other car.
Trying to work as fast as I dare without breaking alot of things.
A large amount done and alot left todo.
-T
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it's pouring buckets outside today, so before I head over (and hope the rain stops) I made up the exhaust manifold->turbo gaskets out of some copper flashing I have
the material
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100821_turbo_gaskets/PIC-0309_640.jpg)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100821_turbo_gaskets/PIC-0310_640.jpg)
In progress
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100821_turbo_gaskets/PIC-0314_640.jpg)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100821_turbo_gaskets/PIC-0315_640.jpg)
finished.
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100821_turbo_gaskets/PIC-0317_640.jpg)
looks like the rain's not gonna let up though so I'll have to brave the storm.
Still have to anneal the gaskets before I put them together and do some minor adjustment to the turbo to get a bolt to work correctly.
-T
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Made quite a bit of progress today. Got the harness out
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100822_wiringharness/PIC-0319_640.jpg)
Also ran it in the other car, all the wiring has been hooked back into the fuse block.
The heater core is replaced, the one I got was made in china, I am not happy at all about the fitment, materials and craftsmanship of it... ah well, if it fails I'll try and find a better option made somewhere else I guess.
Anyway, the new (very dirty) jetta is near the lift
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100822_wiringharness/PIC-0320_640.jpg)
Also, pulled the old intake and turbo/exhaust/egr cooler
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100822_wiringharness/PIC-0323_640.jpg)
when I pulled the exhaust manifold (I left everything attached since i'll be swapping it out) I think I found where it was leaking, the flex pipe seems to have daylight shine through when I look at it (I didnt' look super close though)
it'll be easy to put the motor back in, there won't be a down pipe *grin*
Anyway, tomorrow morning Cate's going to carpool so I'll be able to run some errands to get a few last bits needed (and hit the DMV up to get this on the road)
The guy who's helping me weld up the intake ran out of gas today when he was working on the intake so he is going finish up the manifold tomorrow and swing out this way with it we'll be able to test fit it.
There is a ton left to do but I'm getting closer
-T
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a huge thanks to Ryan for swinging out today, he helped out more than he even knows!
turbo and exhaust are together:
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100823_tdi_progress/PIC-0327_640.jpg)
Because it hit the transmission mounting bracket I busted out a cut off wheel and got it mounted with the modified transmission bracket... this will need beefing up... or a new one built, I'm not sure which is easier...
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100823_tdi_progress/PIC-0331_640.jpg)
we got the gas tank out and new one in and made a short drain line that took more time than I care to admit to get in... (but it is)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100823_tdi_progress/PIC-0332_640.jpg)
at that point I tested starting and it did!
so I started working on mocking up the intercooler piping, but since I have to get up at 5:30 tomorrrow I'm going to bed.
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100823_tdi_progress/PIC-0338_640.jpg)
-T
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This is awesome. I will use some of your ideas when I run into problems with my 1.6.
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This is awesome. I will use some of your ideas when I run into problems with my 1.6.
I'm glad that it's somewhat of a help *Grin* was wondering if anyone was reading.
I made some major progress yesterday final fitment of the IC piping, my buddy came out to help (a huge help) and we got downpipe fabricated, and last night I was able to test start the car check around for leaks. (I need to get the intake manifold drilled and tapped for a hose barb, I got the incorrect fitting for the tap I have :-/) Should do that this morning.
downpipe tacked up but not welded yet.
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100825_intercooler_and_downpipe/PIC-0342_640.jpg)
front end, I put painters tape on the fenders as I stupidly put the bumper rebar in and managed to ding the drivers side...
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100825_intercooler_and_downpipe/PIC-0345_640.jpg)
here's the air box, I able to route things through the bottom of it (which means I get to keep the oem air cleaner, one less thing to try to find/fabricate...) I had to modify the bottom of the airbox but it seems to at least at the moment work ok. The only other note I have on the IC piping that came with the ebay kit is there are not enough silicone couplers so, if your looking at this kit, buy a couple 90 degree and more t-bolt clamps. I'm planning on having my buddy tig up the piping so there are less coupler's to blow off, but for the moment it should work for testing.
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100825_intercooler_and_downpipe/PIC-0347_640.jpg)
The front bumper on the tdi was cracked so I just saws-alled the crap out of it so it would fit and I could move forward with the testing.
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100825_intercooler_and_downpipe/PIC-0349_640.jpg)
I need to build a different pass side engine mount, I'm not anywhere close to confident in the one that is on there. I'll be buying some thick metal to do this (hopefully later today)
stand by for more crappy cell pics later on
Oh, and last but not least my wife's '00 tdi golf's pass side cv boot decided to put a hole in itself and spit its guts all over the wheel :(
-T
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I'm pretty tired at the moment.
But! it drives under it's own power! I need shocks and struts, the fronts are shot and the rear's aren't mine I'm thinking a cupkit or coil overs... I think the brakes are sticking as well (e-brake perhaps?)
no exhaust leaks (that I could tell) I welded shut the o2 sensor ports with some bolts last night (did I say that already?)
I ran out of space and deleted all the pics I hadn't d-loaded (pics of the engine mount, etc) oops ... so that sucks
But they're only crappy cell pics anyway.
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100826_backtogether/PIC-0360_640.jpg)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100826_backtogether/PIC-0361_640.jpg)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100826_backtogether/PIC-0362_640.jpg)
I'll have to work on the bumper (not liking how the ic sits, but it'll work until I get a chance to reposition.)
anyway I have to run, will post more updates later.
-T
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Well, after a long weekend (including a wake) I managed to get time to work on this yesterday afternoon
I haven't gotten the suspension done, but last night I did get the front brake pads changed. The old front pads ebc green stuff had separated from the backing plate (is this normal, or only when being thrashed by a turbo vr6?)
Of course I've heard now that ebc aren't exactly getting stellar reviews after I bought and installed their red stuff pads. (hopefully they'll do ok for street driving.)
cleared the codes for the engine, and everything appears to be happy (no more flashing glow plug light!)
put the grill in and got the door panels in place. There are still a few pieces missing that I need to look for (or I need to get.)
Tightened down the front suspension nuts and took it for a 30-45mph run up the road to about 2k rpm. Since it was night, and I did get high-beamed when my low-beams were on, so they must need to be adjusted...
I checked again and the drainline is leaking so I will have to come up with a better solution. I'll either revisit how I've got things run there, or look into a pan based drain. I was thinking braided stainless might be what I need to go with. (basically something with more flex in a small amount of space)
And finally started running the wiring for the egt, boost and oil pressure gauges, hope to have the rest of the interior in tonight and will look at what it would take to swap over the front suspension as I won't have anything to roll the other shell around on if I remove the rear.
That said, I've let things start run and warm up and it sounds good, fairly quiet and no weird rattles. also, it needs an alignment badly (but until I get the suspension figured out it'll have to wait)
-T
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well, the wiring took longer than I expected, things but the dash is in place (good enough for testing anyway)
The probe works with the vdo egt gauge so I have an egt gauge now! (well one that works) it seems very responsive which is nice!
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100831_dash/PIC-0380_640.jpg)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100831_dash/PIC-0382_640.jpg)
and a pic of the current front end.
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20100831_dash/PIC-0379_640.jpg)
side note: Man my cell phone's camera sucks
Now once I got things back together and usable I took it for a test spin, as I mentioned, the egt gauge seems very responsive, I'll have to do some research as what a good temp range is.
The one thing I noticed (and was not happy about) when I go to start out on the road that things kinda 'stalled' out for lack of a better term, I let off the gas and stepped on it again and it goes. Just seems to be the initial 'stumble' after it seems to push a decent amount of power, although the front shocks are kinda sucky so I'm not slamming on the gas. I managed to pop a boost tube. Got it back together, re-test drove.
Need to hook up the n75 valve so things will work as it should, I haven't gotten that far. (perhaps that would have helped avoid a blown boost tube oops. I let right off the gas once it happened and idled back to the driveway.
Still I'm fairly happy with the progress I've made so far, hope to finish up things tomorrow night interior-wise.
-T
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oil pressure sensor is in place and working & n75 valve is hooked up, took a quick run down the road, it was fairly dark so I was not able to tell how bad the smoke is behind me, today should be able to do so.
That said, it seems to pull hard and the n75 appears to bleed off boost around 10-12psi. On the handling front, the whole car feels 'squirrely' and i'm not sure if it's the sway bars, current suspension or something loose so I've got it back up on the lift to will try and figure out what's up with it today.
I scanned the car for codes and there were a couple, something related to some open wire, the other with a boost issue (which I imagine got thrown when I blew the boost tube) I've cleared them then my laptop died... so once I charge it we'll see if they have come back.
Also, I put the airbag in and for some reason the air bag light will not go out, (after I cleared the airbag codes) Now the light is on, but there are no codes ... strange.
last but not least, for some reason the rear cd changer will not spit out it's cartridge (maybe the radio I have isn't the right one that works with it) or perhaps it's just shot...
It's hot and nasty out, so getting this far last night was pretty decent.
-T
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So, after test driving the car and realizing how bad the suspension in it is, and based on the time I have. I've decided to order a new suspension setup. It will be easiest from my stand point as the parts car is no longer in the garage (nor do I have access to the lift, it's currently occupied) and I don't have a junk rear set of shocks/struts to put in to roll the other shell around on.
Any suggestions on a good setup, since it's my daily I'm concerned with ride quality. I'm budgeting ... I have no idea what I'm budgeting on the setup. suggestions welcome.
-T
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Just ordered a h&r sport cup kit, should be decent, it's what I ran in my old GLX and was happy with the handling of.
-T
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So, I've driven this to work the past two days and it's made it there and back again and back to work this morning. I got the interior buttoned up (for the most part) haven't had a chance to take any pics, but everything appears to be working ok. There's an intermittent "00575 Intake manifold pressure control difference" code, but I haven't really pushed the boost much with it. I want to get my suspension replaced so I am confident with the handling.
But, other then handling, the car appears to be working well, water temp is where it was before the swap, oil pressure is good, etc.
a couple things that need attention (in no particular order):
- Chip tune, work with Mark (Malone Tuning) to get a custom tune for the current setup now that it's in place and running.
- minor turbo drainline oil drip issue, I need to either re-make it or remove/re-install to see if I can re-seat things. (not holding my breath on that, so I'll most likely have to remake the line.)
- I the intermittent boost pressure issue that keeps throwing a code. I need to track down what's up with that.
- I need to make a harness adapter for the gas gauge to work correctly.
- I think the rear pass side brake caliper is freezing/frozen (may have a lead on a spare set of rear calipers in case I'm not able to free up the sliders)
- needs an alignment (I'm waiting to put the suspension in, but I don't want to wait to long.)
- finish getting the final interior bits
- adjust the downpipe/exhaust to the center of the tunnel, currently is a tad close to the edge and rattles every now and then.
-T
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very good job ;)
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Has been a long past couple months, my wife landed a new job (the current one is crazy stressful because boss yells alot, really isn't all that professional.) my grandfather passed away, and I moved large old machine tools (a couple big lathes and a small mill) into my garage...
had boost issues where I'd only be able to get 10 psi (frustrating) tried many things ...
Turns out that my boost issue was not fixed with the t-bolt clamps (no surprise there) and I haven't had a chance to put my silicone 45 couplers in yet. But I was able to pinpoint the cause (as of last night!)
I caught up with a friend at his shop last night and we figured out where I put things together incorrectly (oops) the culprit turned out to be the top hose on the n75 valve. During the swap, I had Tee'd it into the pressure hose that went to the ECU. The upper port of the n75 valve is supposed to go to just after the maf or into atmospheric pressure. Where I had things plugged in caused the ecu to bleed off pressure before it normally would (interesting find) was good to have a second set of eyes on the problem as I am still a newbie at turbos.
Anyway, We pulled and plugged the line from the T to the n75 to prevent a boost leak and went for a spin. Boost was fairly instant, jumped and hit high 18-20psi boost then promptly blew a boost tube. Back to the shop, put that back on, got a better grip on the tubing w/the t-bolt and now the boost band builds at about 2k rpm, up to 18psi then bleeds down to and holds at 15. (as it did before this swap!)
The power is back and boost couplings appear to be holding. There is very minimal smoke behind while pushing high boost (and I haven't hit WOT as it's really wet out here.)
Now I can finalize my build
- remove the stuff that's cobbed together
- get my intercooler raised up to where I want it so I can get the front bumper
-get paint done
- and more boost which means new chip based on the current setup.
I was thinking 20 to 24psi but my buddy who helped me get this figured out thought since turbo is from a 5 cyl (eats more air) since this is a 4 cyl maybe this one could push higher boost. (with the fmic, larger injectors etc.)
I figured now that I have things to where I can do logging and i've got an email into Mark to get his feelings on the subject.
I'm excited about how this is turning out.
-T
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replaced my ignition switch last night it was showing classic signs of failure.
today I tackled the FMIC
FMIC final placement
brought my charged camera, forgot the flash card... you get the crappy cell phone pics
before
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20101017_fmic/PIC-0456_640.jpg)
during
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20101017_fmic/PIC-0462_640.jpg)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20101017_fmic/PIC-0459_640.jpg)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20101017_fmic/PIC-0470_640.jpg)
after
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20101017_fmic/PIC-0475_640.jpg)
all the pics I took
http://fuslit.org/photo_gallery/index.php?album=misc/car/tdi/20101017_fmic/ (http://fuslit.org/photo_gallery/index.php?album=misc/car/tdi/20101017_fmic/)
started cutting up the other bumper cover and found that the corner was cracked :boo:
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20101017_fmic/PIC-0474_640.jpg)
but it looks like I'll be able to get a new bumper cover to fit with minimal cutting (some will be necessary with how I made things fit.) took it for a spin boosted to 20-22 psi then it bled off, didn't blow so I consider it a success!
I'm on the home stretch with this thing!
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Well... since i've last posted, I hit / killed a deer.
(http://www.fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20110128_tdi-damage/PIC-0131_640.jpg)
Both the body shop and I initially thought the car was totaled (would have been if I hadn't kept receipts ... 33 pages of them *grin*) So, I told the insurance company that I was interested in fixing the car. Either by having them fix it, or me buying it back and fixing (my preference would be to obviously fix it and not have a salvage title. My 33 pages of receipts brought the value of the car high enough that the car did not get totaled (and the body shop fixed it.)
It got a new front end. (fenders, hood, bumper, etc) and I learned alot about body shops and repair (both good and bad)
(http://www.fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20110219-mid-repair/PIC-0152_640.jpg)
(http://www.fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20110219-mid-repair/PIC-0153_640.jpg)
(http://www.fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20110311_tdi_repaired/IMG_1808_640.JPG)
here's how it's sitting now more or less finished body wise.
(http://www.fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20110512_done/PIC-0248_800.jpg)
(http://www.fuslit.org/photo_gallery/picKLE-cache/misc/car/tdi/20110512_done/PIC-0253_800.jpg)
and I'm about to order the new chip and map sensor from Malone to push 26psi of boost.
I have a few interior things I need to work on finishing up and I am thinking about getting some small spacers for the rear wheels (5-10 mm?) to push them out slightly but i'm glad I've been able to save it from destruction. It's been great to drive so far lots of power with the current chip from Malone and I can't wait for the next upgrade to take advantage of the turbo and fmic!
-T