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Messages - Smoker

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Someone more knowledgeable might chime in, but I think 200ish hp is widely regarded as the ceiling for stock internals.

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TDI Engine -General Info / Re: 98 AHU problems... Won't rev
« on: February 13, 2018, 12:19:59 pm »
Is it MK3s that have an issue with the wiring for the timing advance solenoid being rubbed off by the corrugated wire wrap?
Hmmmm... I haven't heard of this. But they sounds plausible.

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mTDI Mechanical TDI Conversions / Tdi - > m-tdi mk3
« on: February 08, 2018, 03:33:25 pm »
Has anyone here converted a mk3 tdi car to m-tdi? I've done plenty of reading on m-tdi conversions, but it seems that they all go in a car that was either gas, or already mechanical diesel, etc. I have a Rover pump on the shelf, and I understand what needs to be done to run it on an AHU. I'm asking about how it pertains to the car itself. It seems like there wouldn't be much to it... Get a pedal assembly from a 2.0 gas car, get an accelerator cable for a mk3 AAZ, and that's about it? What am I missing?

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TDI Engine -General Info / Re: 98 AHU problems... Won't rev
« on: February 06, 2018, 07:44:24 pm »
I checked and cleaned all grounds.

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TDI Engine -General Info / Re: 98 AHU problems... Won't rev
« on: February 03, 2018, 03:35:00 pm »
One thing I've noticed: timing and iq values seem to 'jump around' more than others I've seen.

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TDI Engine -General Info / 98 AHU problems... Won't rev
« on: February 03, 2018, 03:10:03 pm »
Well I'm stumped. I just picked up a mk3 jetta. The car itself is in really good shape, and completely unmolested. 248k miles.

When I got it: it would start up and idle perfectly. It would rev to about 1800 rpm smoothly, and anything above that it would break up/misfire/etc and blow all kinds of white smoke. Not coolant, but white smoke that would indicate a fueling issue. Previous owner replaced the turbo, cleaned intake manifold, got frustrated and decided that it had a blown head gasket because of the white smoke.

I have vag-com. No codes except glow plug monitoring.

What I've tried:
-looked at all wiring I could find. No apparent issues.
-unplugged maf. It might run 5% better unplugged, but still very bad.
-checked static and pump timing. Cam was a bit retarded, but pump was within spec. I adjusted static timing to spec. Result: no change. Still no codes.
-eliminated cat converter to make sure it wasn't clogged. It wasn't. No change.
-swapped ecu with a known good one. No change. Still no codes.
-swapped pump with a known good one and re-timed. No change. Still no codes.
-swapped all 4 injectors with a known good set. No change. Still no codes.
-removed intake manifold to make sure intake ports in the head weren't clogged. Clean as a pin.
-removed downpipe to check for something silly... Blockage or gasket installed backwards or something. It wasn't.

I'm not a diesel expert, but I'm not a newbie either. I'm 99.9% sure this is an electronic issue, not fueling or compression.

I'm out of ideas! Any chance a bad dbw unit could cause this??

I'm about to throw in the towel, get an accelerator pedal and cable from an AAZ car, and try out this Rover pump I've had sitting on my shelf!

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Parts for Sale/Wanted / Re: 11MM Bosch mTDI pumps - LR 300TDI Pumps
« on: November 18, 2017, 12:37:05 pm »
Has anyone here actually bought a pump from this guy?

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IDI Engine / Help me brainstorm
« on: February 11, 2016, 08:39:42 am »
Hey, guys.  Some of you have seen my thread where I asked about my intermediate pulley failure.  It's a 90 Jetta, originally gas, with an eco engine and trans, td pump, and K24

While the car is down, I'm debating some changes.  This car is new to me... I've only put about 500 miles on it.  My first impressions are

- K24 is far too laggy (I may see if timing adjustments help at all, but I doubt I'll be happy with it)
- Gearing is much too short (eco trans)
- When the boost finally comes on, it feels great.  One of the PO's claims that the pump was worked over by Giles, and I'm inclined to believe him.

My questions:
1. Turbo: would a vnt15 with some sort of mechanical vane control transform this car as much as it seems like it would?  I've been drooling over one of the Holsets that everyone seems to like so much, but the reality is I've got 3 vnt's sitting on my shelf.  With the K24, I'm seeing almost no boost until 2200-ish rpm, then by the time I'm at 4500 rpm, my 30psi boost gauge will be pinned.  Seems like 5 psi just above idle with a nice linear rise to the high teens at full tilt would be fantastic.  I've got the ability/resources to build a rear motor mount that will accommodate the turbo, and figure out oil lines, boost lines, etc.  The only part I'm still lost on is the vane control.  I've been digging around, but it seems like all the threads I can find on this are a few years old now, with broken pic links, etc.  I know this is a hot topic around here, so any help is appreciated.  (side note: most of the vnt vane control links in the FAQ give me a "you don't have permission to view this" message)

2. Transmission: I have a tdi 02j here, with shifter box, etc.  Have any of you run a similar trans with a 1.6?  I'm guessing that it would be pretty painful with the K24, but better with the vnt.  I know I'd have to do something about a trans mount, and hydro clutch, and axles, and, and,... I just can't see driving a car like this and only getting mpg's in the high 30's to low 40's.  If I can't get 45 on a bad day, I'll be better off selling the car and using my ALH Samurai as my daily. 


IDI Engine / Re: Intermediate shaft pulley failures, anyone?
« on: February 11, 2016, 07:48:53 am »

How loose does the injection pump sprocket feel/ Lots of side-to-side movement?

I finally got the car home late last night. I'm planning on digging into it today. I'll report back.

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IDI Engine / Re: Intermediate shaft pulley failures, anyone?
« on: February 09, 2016, 11:12:47 am »
Also, yes, all other pulleys I've seen have had holes in them. I'm really starting to think that the broken pulley was a cheap aftermarket replacement, and the second pulley was worn before I ever put it on.

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IDI Engine / Re: Intermediate shaft pulley failures, anyone?
« on: February 09, 2016, 08:36:07 am »
Fair points. This car has definitely been 'around the block'. And now I see what you guys are getting at with the thrust bearings. I'm hoping to get the car home tomorrow... I'll pull it apart and report back.

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IDI Engine / Re: Intermediate shaft pulley failures, anyone?
« on: February 08, 2016, 03:59:32 pm »
I'll definitely be a little more thorough in my inspection of the bottom end the second time around... Why do you ask about thrust bearings specifically?

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IDI Engine / Re: Intermediate shaft pulley failures, anyone?
« on: February 08, 2016, 03:58:13 pm »
All the intermediate pulleys I have are aluminum... (?!)

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IDI Engine / Re: Intermediate shaft pulley failures, anyone?
« on: February 08, 2016, 11:39:13 am »
Unrelated: I got in touch with a few of the PO's... One of them claims it has a Giles pump. Is there any way to verify this? I've had quite a few n/a 1.6's and tdi's but this is my first 1.6td, so I don't really know how it should feel. The pump looks rough, and if it was rebuilt, it was a while ago. It does make 30 psi pretty easy if you put your foot down, though.

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IDI Engine / Intermediate shaft pulley failures, anyone?
« on: February 08, 2016, 11:31:21 am »
Pardon the long post, but I'm trying to be thorough.

I picked up a mk2 recently with a 1.6td. Eco engine with pump and turbo from a regular 1.6td. I bought it sight unseen with what sounded like a timing belt failure... it was clean and cheap enough that I didn't really care too much what was wrong.

So I dug into it and found this...

My first thought was that someone over-torqued the bolt and/or over-tensioned the belt. No worries, I have a few parts motors here... I ordered new i/m shaft bearings and pulled a complete pulley and shaft off of one of my other motors (as an assembly... I didn't take the pulley off the shaft). To my surprise, the bearings looked perfect when I finally got to see them. So I put it all back together with a spare good head.

It was running great until I found out the hard way (and 350 miles from home) that you're supposed to re-torque head studs.  But before I realized that the head gasket was giving me issues, the water pump started peeing. So we found an auto zone and I swapped it out in the parking lot.

When I pulled the intermediate shaft pulley, you guessed it... The keyway was fubar'd, and you could tell the pulley was starting to spin further and further on the shaft. I didn't think to get a pic at the time.

So that was a really long story leading up to a really simple question: Is there something wrong with my engine that's making it eat those pulleys?

I kind of assumed that the current pulley had that wear when I installed it, and it was a coincidence. When I called my parts guy this morning, he said he's never heard of those pulleys failing like that. He's thinking that the oil pump and/or vac pump is tight, putting too much force on that pulley. I spun it by hand the first time I was putting it all together, and didn't notice any abnormal drag/resistance.

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