1.6d to 1.6 ecodiesel

[meanvw]

So here's my 83 Rabbit LS.  Pulled out of a barn 2 years ago.  



Rebuilt motor, head, injection pump, injectors... etc.. last year  $322 in parts... mucho labor on my part.

http://forums.vwvortex.com/showthread.php?4658651-1.6L-Engine-Rebuild

This thread shows a little more of putting together the body and such.

http://forums.venommotorsports.com/default.aspx?g=posts&t=2272

Have got 11,000 miles this year since the re-build .  Use it to commute 160 miles per day.  Been averaging 49.3mpg over last 4700 miles.

Running anywhere between B5 and B20 biodiesel blend.  Have a very nice Biodiesel manufacturer/filling station on the way to my father's house in northern wisconsin.  Stop by there and fill up my tanks and some pails every couple months when I go that way.

http://www.bioblendfuels.com/

So I happened onto what I thought was a good deal off craigs list, K14 turbo, intake and exhaust mani, oil lines, oil pan with return line for $200.
Today I found another ecodiesel in a junk yard and got the air intake, oil filter housing, and some of the crank breather stuff.
Waiting on the MK1 exhaust elbow and a brosal td downpipe that I bought from user ilikevwdiesel on here.

In the mean time, am cleaning up and gathering parts.
Opened up turbo, cleaned it all up, inspected, no shaft play.  Lapped the waste gate. Waiting on new seals to get that together.

So here's the parts hoard.



The goal... little more power, little more mileage.

That's all I've got for the moment.
Just hoping to get input from the experts on things which I might want to do/look at to make the journey easier.
So if you've got any thoughts or links to shoot my way... please do.

Hoping once all parts are together that I can knock this out in one weekend.  
Have got other cars to drive...so I can afford to have it down longer if need be.

[nathan_b]

oil cooler hoses?

nice looking bunny
k14 is the beez-neez

looks like an a3 air box,
won't even be close to fitting.

You can use a mk2 td air box, aaz intake hose (fits k14) and twist the hose a little and it fits well in a a1

[JerryGTD]

That's the MK2 ECOdiesel air box and the proper intake tubing for the K-14.

[meanvw]

I believe these are to correct oil cooler hoses.  Searched for those and found them in parts boxes I have from some other cars that I parted out.  Definately saved me some time finding them on install day, thanks for that thought.


I would assume that I am going to want to run the oil cooler?  I guess why not since I have it.
The 1.6na did not have an oil cooler.  Seems like it will be tight, but with the extra depth of that oil cooler, the filter itself is going to be real close to both the front motor mount and the radiator support. Did the MK1 TD's have oil coolers?

All the parts so far are all from MK2 jetta eco diesels.  I test fit that air box in the rabbit and seems like it should fit pretty well.  Without the turbo in the car I cant picture exactly how far forward or back it will have to sit... but one thing for sure I'll need to relocate the fuel filter.  Would be nice if that fuel filter fit eco diesel style right behind the air box between airbox and the strut tower. Which reminds me to go look at and find some tubing to relocate it.

[R.O.R-2.0]

I believe these are to correct oil cooler hoses.  Searched for those and found them in parts boxes I have from some other cars that I parted out.  Definately saved me some time finding them on install day, thanks for that thought.


I would assume that I am going to want to run the oil cooler?  I guess why not since I have it.
The 1.6na did not have an oil cooler.  Seems like it will be tight, but with the extra depth of that oil cooler, the filter itself is going to be real close to both the front motor mount and the radiator support. Did the MK1 TD's have oil coolers?

All the parts so far are all from MK2 jetta eco diesels.  I test fit that air box in the rabbit and seems like it should fit pretty well.  Without the turbo in the car I cant picture exactly how far forward or back it will have to sit... but one thing for sure I'll need to relocate the fuel filter.  Would be nice if that fuel filter fit eco diesel style right behind the air box between airbox and the strut tower. Which reminds me to go look at and find some tubing to relocate it.

all TDs had oil coolers (warmers) and lots of gassers had them too.. they dont really cool the oil at all.. they more help for warming up.

the longer, bottom hose is from a gasser VW, and they wont even come close to fitting a diesel.. the bottom half will fit fine.. but the diesel bypass hose enters the bottom of the water neck. where as, the gasser bypass hose comes in the water neck from the side..

that hose, even if you had the correct water neck for that hose, it wont work.. the water neck and hose will hit the injection pump and lines..

theres a bracket on the front passenger side fender well.. you can modify the fuel filter bracket a bit and use the washer bottle bracket..

[meanvw]

OK, got to do some work this morning.
Put turbo back together after cleaning and inspecting everything.
Have a couple questions/comments now.

I am sure that when I took this apart that there was no gasket between the exhaust manifold and the turbo.  The surfaces appear to be very flat and do mate up very well.  Just want to verify that there is or is not supposed to be a gasket here (where finger pointing)



Next, and this is more of just a comment if someone else is doing the same.... I got the MK1 exhaust elbow from user ilikevwdiesel on here (thanks!), and needed to clean up the casting on both it and the turbo housing because it the 2 parts were in contact enough that I could not bolt down the exhaust elbow to the turbo housing.  Orange dot indicates where there was contact.




Next question.

It seems that there is a slight "buffer" of space between the turbo and the intake manifold.  Am I missing some sort of shield, or is this the way it is.  If there is a shield, what does it look like, what does it attach to, and anyone have one / thoughts on making one.  Or even necessary?



Last thing for now, this was part of a group of eco-diesel parts I got from a guy.  I'm assuming it's a heat shield between turbo and firewall?  Where did this thing originally attach to (the turbo housing, or the firewall?) 

[burn_your_money]

No gasket required. Some people use a little RTV.

Yes there is suppose to be a heatshield in there. It goes under 2 of the intake manifold bolts and attaches to another piece that goes under the 2 bolts at the neck of the intake manifold.
You can see one here
http://img.photobucket.com/albums/v603/burnyourmoney/DSC09770-1.jpg

The heatshield goes on the firewall. It has 2 tabs that go under the weatherstripping seal and 2 holes that hook in where the brake line clips are. You won't have those on a mk1 AFAIK

[meanvw]

Took the day off work today.  Have my son's first high school football home game tonight, and also this local team (Green Bay Packers  ) is also playing tonight! 

Well the morning started a little something like this...



And a couple hours later looks like this



Things I've discovered so far...
I need to go back to junk yard Saturday for the turbo diesel valve cover.  The TD breather set up is different- didn't notice that.
Also need to grab that proper coolant hose from the head to the oil cooler to the water pump (thanks for pointing that out R.O.R-2.0)

Also found out the MK2 airbox is not going to work like I thought, so will have a short section of pipe made up tomorrow to the right diameter and put a cone filter at the end of that stock eco-diesel turbo inlet pipe.

N/A exhaust toilet bowl exhaust piece for sure does not match up to the TD exhaust.  The NA toilet bowl sits too far forward.  I've got the TD toiletbowl downpipe, and will get that expanded tomorrow so i can cut my current exhaust and slip it over, clamp it down.

Still quite a bit of work, but should be done by the end of the weekend.

Taking the rest of the day off of the project... maybe do a few more hours tonight if I feel up to it after the game.

[bagpipegoatee]

Looks great.

If you need anything, let me know.   I'm doing a similar setup in a mk1 right now and am also in WI.

[meanvw]

Another junk yard run today to get the proper valve cover, and the proper hose for the oil cooler to the head.
Auto parts store for a cone filter and an oil pan gasket.
Hit the muffler shop on Friday to get the new down pipe end expanded to fit over top of the stock exhaust.  Also had them make me up a short piece of metal pipe=3" on one end, 2.75" on the other.  This will be the transition from the turbo inlet pipe to the cone filter.

Used this to insulate/reflect turbo heat off the back of the intake manifold in lieu of finding the correct heat shield at the junk yard.



And here is how it currently sits:


Still have the oil pan to put on. Got the old one off.  Happy to see that after 10,000 miles after my rebuild, it's clean as a whistle inside the motor and at the bottom of the old oil pan...  Nothing in the oil screen... makes me happy.   

Still left to do:
Relocate fuel filter... still thinking about that.
Install turbo oil pan, and line to bottom of turbo.
Install new oil filter housing, drain coolant system, new hoses, install feed line to turbo.
Install downpipe and connect exhaust back up.

Hopefully back on the road by Monday is the plan.
Been driving the G60 16V Scirocco.  Loving some power, loving some boost.... Still love the diesel rabbit... but this is still my baby.

[meanvw]

Also...



I think I know what this little piece that is in the crank case vent line that has a 2 prong electrical outlet on it is.
When I built the G60 gasser, there was one of these in the crank case vent line, and it was supposed to get power when the car was running.  Was supposed to heat up and help burn up oil that was in the crank vapors before it re-circulated into the compressor. 
Same thing on the turbo diesel??  Just feed it switched power and ground? 

[the caveman]

yes just hook up to 12v switched with ignition.
BTW nice 'rocco. It's exactly the one that we unsuccessfully tried to destroy the engine by driving it without any oil. we gave up after 1 1/2 hours

[meanvw]

Goal achieved!  Only needed to drive the Rocco to work 1 day.  Started Thursday, worked on it a few hours a day, finished up tonight.

Only drove about 10 minutes, got up to temperature.  Was dark, brought it back home to check everything over again.  Definitely feels like has more power.  Less smoke.  A little quieter. Very cool sound as the turbo winds up.  Different sound from a turbo gasser.

[meanvw]

160 miles today.  2 minor oil leaks fixed.  1 minor coolant leak fixed.  Like how it runs so far .

Question of the day is:  I have a boost only gauge on my scirocco that I may take out. Question is, what should the turbo diesel read - as in almost always reading boost? Or do I want a gauge that reads both vacuum and boost.  Why?

[nathan_b]

if diesels have vacuum, you have a problem, only boost. but it will rattle on the stop pin, so get one with vac gauge too