Author Topic: Jetta project 200 (Read 131882 times)

1outof5 · « **Reply #105 on:** December 31, 2008, 12:46:36 pm »

Called my Dad, where the car is, to get a pic ... the fuse box only has the one wire hoock-up, sorry

TurboJ · « **Reply #106 on:** January 01, 2009, 11:25:51 am »

Quote from: "1outof5"

Called my Dad, where the car is, to get a pic ... the fuse box only has the one wire hoock-up, sorry

But hey, thanks for your help anyway! You mean it only has the thick red wire connected to it on either side? If so, can you confirm where the other one goes, the one that's not connected on the glow plugs?

Thanks again!

vwt4 · « **Reply #107 on:** January 01, 2009, 04:03:59 pm »

Lovely project!

Can you elaborate exactly on how you plan to have the supercharger cutout when the turbo has built boost?

is it some kind of clutch to disengage it or what?

TurboJ · « **Reply #108 on:** January 01, 2009, 05:02:37 pm »

The supercharger was on my friend's last engine evolution.
My car doesn't have a supercharger, just a simple old school Schwitzer turbocharger. As for the supercharger cut-out, if Aki is reading this, he can answer that one as it was his project

rallydiesel · « **Reply #109 on:** January 02, 2009, 02:17:59 pm »

Did you find out what that is? I can't really see from the pics.

TurboJ · « **Reply #110 on:** January 02, 2009, 02:38:10 pm »

Quote from: "rallydiesel"

Did you find out what that is? I can't really see from the pics.

It's the glow plug fuse box, but the problem is the wires attached to it are a bit mixed up. I know where the three small wires go, but the thick plus feed is something I need to sort out. I'm trying to make the engine room a bit more organized and 'clean' so I'd like to move the fuse to the other side of the fire wall.
But there has to be a reason why it was fitted where it is?
Then on the other hand, mk3 TD:s did have the fuse next to the main fuse box, under the dash..

Now if I only could find a good deal on a Bentley manual. My current manual doesn't cover the diesel engines at all so it's slightly difficult to find information about glow plug wires on it

To update the project story, my Wiechers stress bars arrived today:

and this has lead to another problem. I ordered these from a reputable eBay merchant who asked me for the vehicle MY and model variant when I put in my order. I told them I wanted a 16V upper front bar, but now thay have sent me a 8V one :evil: And the great thing is the eBay shop isn't there anymore so I can't make a complaint.
When did that ever happen? I store with a +20.000 feedback rating went out of business exactly after I had put in my order.

It seems I'll just have to modify this bar to fit my TD. That should give me an opportunity to weld a firewall triangle brace on it though, so maybe it's not all bad.

theman53 · « **Reply #111 on:** January 03, 2009, 04:44:14 pm »

Quote from: "TurboJ"

I know one tuned VW 1.9 diesel engine that has a twin-inlet manifold that you described. Apparently works OK as the car makes 250 hp.

I will PM you the math stuff when I get in touch with the guy (I don't have the right formulas myself).

Give me the goods. I am almost ready to build a LOG manifold but need some stuff on how numbers and stuff should work. Let me know if you find anything. OR you could just send me your intake and I could copy it an send it back

Your car will be done before mine though so that might not work
:lol:

TurboJ · « **Reply #112 on:** January 04, 2009, 10:31:05 am »

Sold my gearbox yesterday.
Aki sourced a Passat 1.9 TD that he's dismantling for parts so I got the 02A gearbox! Now I guess I won't have to worry about the g/b exploding.

The conversion is pretty complex however:
I need pedal assembly from the Passat, as it has a hydraulic clutch. Then the master and slave cylinder, shift linkage and gear lever etc.
Then I'll have to find suitable drive shafts too. Does anyone know if any other than the Golf G60 ones will fit?

I'll need a different clutch too. I'm going to try a 228 mm G60 clutch with a stiffer pressure plate and a grippier disc, along with a lightened G60 flywheel.

That's gonna require quite a few hours in the garage to finish, but it should be worth it!

theman53 · « **Reply #113 on:** January 04, 2009, 11:07:12 am »

I used to have a link to a guy that did this in a write up. The one thing I remember is that he used a hole saw to cut the firewall for the hydro clutch pedal and system. The link is no longer working, but there was something about the axles as well, but I can't remember now.

MJF · « **Reply #114 on:** January 04, 2009, 12:16:26 pm »

Quote from: "TurboJ"

Now I guess I won't have to worry about the g/b exploding

My 02A :lol:

You can use Passat clutch cable too if you don´t want to convert hydro-clutch.

TurboJ · « **Reply #115 on:** January 04, 2009, 01:06:53 pm »

Quote from: "MJF"

Quote from: "TurboJ"
Now I guess I won't have to worry about the g/b exploding

My 02A :lol:

You can use Passat clutch cable too if you don´t want to convert hydro-clutch.

Hmm.. Any idea why that broke? How much torque did you have again?

MJF · « **Reply #116 on:** January 04, 2009, 01:23:10 pm »

Quote from: "TurboJ"

Hmm.. Any idea why that broke? How much torque did you have again?

Probably all the 2nd gear burnouts and beating

Not much torque, 350-370nm estimated maximum.

TurboJ · « **Reply #117 on:** January 05, 2009, 06:30:43 pm »

My inlet manifold is almost ready:

The combination of a 1Y inlet and a round, secondary plenum makes this thing really flow. And I think it'll look pretty nice too once it's all done.
I'm going to take some strain off Aki and do the polishing stuff myself :lol:

The cylinder block is also ready now.
Next weekend Aki is coming over and we'll be test fitting the engine so I can start to fabricate the downpipe and boost pipes. Now that should be fun!
Aki has also promised to do some serious spot-welding on my Jetta body, so it'll be a lot of work for one weekend.
Can't wait to see the finished exhaust manifold too - especially if there's time to get it ceramic-coated for the weekend. Well, if not, I'll just have wait for another time

Next thursday I'll booking a time at a paint shop. A deadline like that is sure to boost the progress of the body repairs. Soon the car will gleam bright, proud to really be Tornado Rot once again.

I'm starting to become somewhat worried about my stock rods again..
Just think about it, people have 170-180 hp with 1.6 heads, stock cams, stock manifolds and small core pumps - I'll have a seriously modified 1.9 head, a custom cam, a very efficient inlet manifold and a good exhaust manifold too, along with a modified large core pump.
This means that the 200 hp target is just all too easy to reach!
In fact, the only thing on my engine preventing it producing 230 hp is the turbocharger. I seriously hope that the Schwitzer turbo won't spool too quickly - otherways I'm certain the rods will bend or crack.
Just one little thing to keep me preoccupied... :roll:

On the positive side of things, I'm thinking this car could be pretty quick once it's done. If it makes 200 hp and 350 Nm torque and weighs in 1000 kilos, then it'll have similar hp per ton and Nm per ton than my old Saab Turbo. That car did 0-200 km/h (0-125 mph) in 19.6 seconds. That's period Porsche 911 territory.

If you really think about it, a 1.6 TD mk2 Golf / Jetta is a VERY smart basis for a fast road car. Simple, easy to work on, cheap to service and to modify, robust and great in handling. Can do 55 MPG, can do 240 km/h... Add to that the classic looks and all that pedigree - It's perfect really! Those who rant on about 'it's crazy to put all that time and money into such cheap, old car - they just don't know what they're talking about.

I'm so anxious to get behind the wheel of my beast! :twisted:

theman53 · « **Reply #118 on:** January 05, 2009, 07:07:44 pm »

your making me think that my goal of 115HP is attainable. I have a fully ported 1.6 mechanical head, ported exhaust, Giles super pump, fresh .020" overbore, KKK24 turbo, and I will have an intercooler and 3" downpipe. And maybe now you might have talked me into an intake...I hope to be 115HP. I need to fix the rest of the AC, floorboards, and well the car first though. Good luck with your 230HP beast. Back to your special thread
I like the way you think.

TurboJ · « **Reply #119 on:** January 05, 2009, 07:26:16 pm »

Quote from: "theman53"

your making me think that my goal of 115HP is attainable. I have a fully ported 1.6 mechanical head, ported exhaust, Giles super pump, fresh .020" overbore, KKK24 turbo, and I will have an intercooler and 3" downpipe. And maybe now you might have talked me into an intake...I hope to be 115HP. I need to fix the rest of the AC, floorboards, and well the car first though. Good luck with your 230HP beast. Back to your special thread
I like the way you think.

I think with those mods you should be able to pass 150 hp with little trouble.
115 hp can, after all, be taken out of a standard engine with a lightly modified pump and a T3 or K24 turbo. You'r car fill fly, make no mistake!

P.S. You've got a private message