Project Potential... variable vane turbo on 1.6l

[jackbombay]

  That 40mm wrench is a head set wrench for a bicycle I am just about positive, if anyone else needs to find one...

[srivett]

My VW dealer wants 70 to 120CDN for a pulley and what's worse is that they don't know which one to order.  They don't know what output my alternator is and it has been converted from an AC alternator to a single belt alternator.  I'll have to find a Bosch dealer in town.

Steve

[fspGTD]

Pic for steve:

[srivett]

Thanks!  I must be using the wrong belt, my 13 mm belt sticks out further on the alternator but looks perfect on the crank and waterpump.  If I were to use that belt it would look okay on the alternator but be deep in the other two pulleys.   :?

Steve

[fspGTD]

An update: Have done some fabrication here and there since my last post (air intake was a big bear of a job), and am now pretty much done with everything except for the exhaust system.  I ran the engine through its first heat cycle today on it's new head gasket and VNT turbo.  (I Dddn't drive it - just ran the engine without any load in the garage until it reached full temperature, then shut it off, and re-torqued the head gasket.)

During the heat cycle, I blipped the throttle a few times to see if the VNT turbo made the boost gauge move.  With only light throttle blips and keeping the RPMs low (didn't want to stress the headgasket on it's first heat cycle), I was able to get 1-2 psi pretty easily!    I found after it warmed up that it put out .2 psi continuously at idle!  I am very impressed with the quick spooling action of the VNT turbo, and can't wait to get the exhaust finished so I can see how it drives.  

[Blades]

You know you juste gave me a real stupid idea

VNT-15 on the 3A (2L 8v Short bloc from late 80s Audi) I'm rebuilding for the cab

I'd keep the linear torque curve those 8v have; hello low torque TQ and HP

Still the VNT-15 on a TD is great

way more low end torque

[TDIMeister]

You'll have to set the VNT actuator rod SEVERAL turns in the negative to prevent huge boost spikes when mated to a gasser...

[rackley]

That alternator pulley will also fit all the way up to a 91 Jetta.  The parts guys messed up and ordered me the wrong pulley (the one you have) and it looks like it would fit perfectly for the non-A/C alternator.  Unfortunately I have AC.

Did I mention how much the AC/Alt setup sucks?  

Ray <-- wishing I could find a non-AC alt bracket

[fspGTD]

Anyone want to host a video taken during the first heat cycle?  [Edit: Blades should be hosting these shortly... thanks Blades!]

3MB, .WMV format, 16VNTD.wmv

I also have a 750KB .WMV close up of the alternator belt, for you guys wanting to see how it runs through a good pulley, alt_belt.wmv

[rackley]

Links don't work..

[fspGTD]

Looks like the yahoo briefcase links broke for whatever reason... perhaps it is not intended for public sharing.

Anyone want to host these videos?  If so, I can e-mail them to you.  I am out of server space necessary to do this myself.

[Blades]

fspGTD: email me the video, I'll host them

webmaster _AT_ poissant _DOT_ org

[Blades]

1.6TD with VNT-15

(right-click, SAVE AS)

http://www.boucanne.com/per_images/video/16VNTD.wmv

Alternator pulley.

http://www.boucanne.com/per_images/video/alt_belt.wmv

[rackley]

That's a VERY clean running alt belt.

Did you get a fresh crank pulley too or no?

[fspGTD]

Nope... crank pulley / TD harmonic balancer is used, probably with lots of miles also.  As they seem to be cut from billet steel though and also have a pretty large diameter with lots of belt wrap, they don't seem to wear very quickly.  Water pump pulley is also just "good used" (I did pick the best looking one I had out of two available though.)

Although not evident in the video, I actually found there was some belt vibration up and down that was visible when viewed more from the side.  But I'm pleased with how the belt looks going through the new alternator pulley.  Also before the video, I added an extra shim to space the alternator pulley out a little bit to bring it into better alignment with the crank and water pump pulleys.  I don't know why it wasn't aligned to begin with.  :?