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#15
by
HarryMann
on 06 Oct, 2006 13:12
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Hehe, Bert, You're about halfway between me and Mr Brickyard on here, who definitely knows his onions, 'cos his workshop is always full of T25s (vanagons across the Atlantic)...
What's famous about Halesowen, there must be something? Aircraft factory? Car factory? Dudley isn't it - aha - I know, the wartime Spitfire and Lancaster factory at Castle Bromwich, that can't have been far away... solid engineering up there, eh? Was! All but gone though I bet and everything redeveloped to naff blandness, canals, pretty lego houses and shopping malls I bet :roll:
Mine's a 4WD T25 Transporter Syncro twincab (Doka) - and we help run the Syncronauts - a club devoted to these handsome and capable off-roaders from VW (nee Steyr-Daimler-Puch at Graz, Austria). With an empty weight of about 1.8 tonnes and the drag of a London bus going sideways, they do need plenty of cruising oomph, but mainly endurance at quite high power settings (read 80-90% of max on the motorway). Hence the original 1.6's though adequate, expire sooner rather than later (definitely soon after 100,000, and don't hear of them getting far beyond 150,000 very often).
Oil cooling and a good eye on water temps too is imperative, with the engine hidden back there under the loadbed. But off-road, these engines are great at pulling you up some quite incredible inclines, with just a light foot on the gas - well usually anyway. A nice smooth torque delivery is helpful when the sheer wheel drag and climbing load get prohibiive...
PS. You're surrounded by T25 owners with similar motors in the back of their buses, campers and pickups..Flat 4 petrols are increasingly being 2.2 Subura'd and more and more are replacing their 1.6 JX TDs with 1.9 AAZs.
Rgds
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#16
by
bert
on 06 Oct, 2006 13:39
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im very close to the longbridge rover plant,i watched the 'overhead tunnel' being took out over the bristol road, a sad day for british industry,i used to be an injection moulder and supply rover,bits of trim etc,the place i used to work for folded.....as did many places round here,not many engineers left now.
My project is a mk1 golf diesel now AAZ powered with uprated turbo etc,we should all meet up next time the sun comes out :roll: (summer) and show and compare motors,
One thing i should tell you van owners,dont buy cheap water pumps,only buy genuine or hepu or bocar,the cheap impellors dont create the same pressure or flow rate as do genuine pumps,i fitted a cheap pump to a AAZ in a turbo diesel transporter and couldnt get the heater hot until i revved to 3000rpm,as the heater matrix is about 3 feet higher than the water pump,probably the same as pumping to the front of your t25'S
Bert
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#17
by
HarryMann
on 06 Oct, 2006 13:51
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I believe I have heard someone else say that about water pumps, and some other parts too... Simon?
How have you uprated the turbo? A bleed on the wastegate line?
1.6 T25s have the KKK turbos don't they, but presume you're using a Garret T3?
Do you know ehere to get the gland-seal and bearing kits cheap (or realistic prices) - have you ever fitted one. I'm told that re-balancing the rotor shaft complete is necessary
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#18
by
deepmud
on 06 Oct, 2006 23:21
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ok - took some pics, did a little grinding. There's a ruler in the pics
I didn't grind all I could - I copied the "offset cone" effect of the 1.6td.
Travel of the pin "as was" is about 8mm.
I made about a 12-13mm ramp, to allow for more boost, but have room for more if I need it. Because it's a cone, I can play with different amounts of fueling.
Grinding was done with a cheap ol' bench grinder, and cleaned up with a small sharpening stone.
More later it's late
Click
HERE
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#19
by
HarryMann
on 07 Oct, 2006 02:22
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Thanks, that's an excellent indication of what we're aiming at to start with.
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#20
by
bert
on 07 Oct, 2006 13:05
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deepmud,that last picture is exactly what i have on my pin now
SWEET LORD the car is fast as hell,my god i didnt expect that much kick when it wound up,and no visible smoke at all,it flies,i cant describe how quick it really is,i drove my 1.6 golf gti mk1 and it is slow compared and the gti is a nippy motor,even before the turbo winds up it is nippy,being a 1.9D.
Tell you what,im putting it into storage for the winter tomorrow,and im gutted after driving it today,i just want to play :twisted:
Im well happy i did the TD conversion on my mk1 golf (rabbit)
Bert
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#21
by
bert
on 07 Oct, 2006 13:14
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harryman,im using a garrett T3,exellent turbo,these guys here recommended i go with one of them,THEY WERE SPOT ON :wink:
The only mod i have done from standard is the aneroid pin,the exhaust 2.5" stainless steel with 1 box on the rear,and the T3 turbo,the boost pressure is going to be measured tomorrow,i have a vw turbo pressure guage i use.
bert
oh the turbo repair kits are on ebay genuine kits too
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#22
by
HarryMann
on 07 Oct, 2006 17:41
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AH, Mines a knackered T2 and will be a KKK soon.
Do you know the A/R and trim of the turbine section, ther are so many T3s about and am sure it needs to match up well with the 1.9 Diesel. Orw as it staight off another vehicle with no mods?
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#23
by
bert
on 08 Oct, 2006 02:15
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The T3 i used is straight off a 1.6 td golf,not the intercooled golf just a standard mk2
the inlet and exit hoses are well bigger than the old turbo hoses,and the old kkk is tiny compared to the T3
Bert
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#24
by
HarryMann
on 08 Oct, 2006 02:24
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Right then, so assuming those pipes can be married up nicely, that T3 has about the right impellers and casings for the 1.9, if you find it goes so well form low down.
I'm bleeding off the wastegate of a T2, to give about 12~13psi, which starts coming in about 2000 rpm and is at full boost just before 3000 rpm.
Have the manifold flanges to be ported to the new larger T3 shape or did you bolt it straight on? Must get my hands on one to take a look, but thought the stud opitch was different, so presume you grabbed the Golf manifold(s) as well.
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#25
by
bert
on 08 Oct, 2006 07:28
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The inlet manifold i used was the 1.9 AAZ,the 1.6 has a bov so i didnt use it,i had to put the inlet flange (where the boost pipe off turbo is jubilee clipped to) onto the inlet manifold so i could use the origional rubber hose (boost hose).
The 1.6 turbo and manifold bolted straight on,with one exeption which was a lump of alloy on the inlet manifold which i hacksawed off :twisted:
this hit the bigger compressor housing.
The oil drain pipe had to be cut and welded to the kkk drain off flexi pipe which was not a problem really,i used the cast iron downpipe which has been modified to accept a bolt on stainless pipe and flexi (golf mk1)
The oil feed pipe had to be bent a bit to fit the T3 but was ok.
All in all easy,same gaskets etc,i used the alloy water flanges on the head off a mk1 as the plastic ones crack,i also had to use the alloy thermostat housing (bottom hose) off the mk1 as the plastic one is thicker and hits a lump of cast iron on the block.
I was going intercooled but i dont see the point as it flies as is :wink:
Bert
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#26
by
HarryMann
on 08 Oct, 2006 10:28
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Well, a lot of good info there, thanks. The truck weighs about 1.8 tonnes empty and gets a move on quite quickly with the T2 (which is now a bit knackered), its really cruising power and durability that I'm after, so keeping charge and oil temps down at higher boost levels , is important. Seemed to need 9-10 psi to cruise at or around 70mph on the motorway - considering intercooling, even water injection.
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#27
by
Baxter
on 08 Oct, 2006 12:05
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I was just going to say avoid any big turbo's, as noted, from what I have read then you are going to be in lag city with anything bigger than a K14 or T2.
You don't need massive boost in yours I don't think, for what you use your truck for your better off with it spooling up quicker and getting the power down at the bottom end, off road use doesn't really need sustained high engine speeds.
With the long gearing on my van (AAR box from a 2.1 with LSD) and the weight of a Westy interior and roof I sometimes struggle with the K14 where I live, hoping the extra lower down grunt of the AAZ will turn it into a more versatile machine, better on the hills and the longer gearing for blatting up and down the motorways.
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#28
by
bert
on 09 Oct, 2006 13:31
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harry you can have the old 1.9 aaz turbo i took off if you want it,its a kkk unit,it worked well,no problems,here if you want to play :wink:
its a k03 i think??
Bert
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#29
by
HarryMann
on 09 Oct, 2006 16:55
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Nice offer Bert, I'd certianly pay the carriage to take a look and it might well end up on the bus!
Thanks