Project Turbodiesel

[hiho]

This is the other golf diesel we picked up in a 2 for 1 deal. Its a bit tidier than the beige car, and has a much nicer tan interior.http://www.vwwatercooled.com.au/forums/images/imported/2009/04/IMG_5102-1.jpg


Up on blocks for some work on the suspension. The plan is for king springs and new dampers, urethane rear beam and front control arm bushes, swaybars, upper and lower front braces
http://www.vwwatercooled.com.au/forums/images/imported/2009/06/IMG_2633s-1.jpg

Wheels courtesy of Golfloon, cheers. We also have a spare set of Cabriolet 5 spoke "tiny teddys"
http://www.vwwatercooled.com.au/forums/images/imported/2009/06/IMG_2635s-1.jpg


Sigma front sway bar going in the back
http://www.vwwatercooled.com.au/forums/images/imported/2009/06/IMG_2638s-1.jpg


This is the project motor, its a 1983 1.6IDI motor from Canada. It arrived here in a caddy. It has been rebuilt by VW Canada but has vast amounts of blowby and oil consumption. Most likely it will receive new pistons. Fortunately oversize pistons are still available for the 1.6 diesel.
http://www.vwwatercooled.com.au/forums/images/imported/2009/06/IMG_5250-1.jpg

In the shed is a 5 speed box, GTI brakes, oil cooler, TD injector pump, turbo exhaust manifold and k14. The motor is going to the machine shop tomorrow where it will be cleaned and measured. Then all replacement parts will be ordered.

[Jarred]

I like where this is heading!

well be watching for sure!

[Water Boy]

Bro looking good! Where abouts in Melbourne you located? If ya get a chance should try and come to one of our meets :biggrin:

[hiho]

Im in Brunswick West. I'd love to catch up with some forum members, let me know when things are happening.

I will be living the diesel tachometer dream, first with a dedicated alternator driven tach, then by somehow driving a petrol tach with the alternator w terminal. Just gotta pull an alternator to bits to tap in a "w" terminal.

Also, as i am short a functional brake servo, what are the prevailing thoughts on larger booster/master cylinder combos. Do any just bolt on, bleed and your away?

[Water Boy]

Monthly meet:

http://www.vwwatercooled.org.au/newforum/upload/showthread.php?t=18969

[Jarred]

Im in Brunswick West. I'd love to catch up with some forum members, let me know when things are happening.

I will be living the diesel tachometer dream, first with a dedicated alternator driven tach, then by somehow driving a petrol tach with the alternator w terminal. Just gotta pull an alternator to bits to tap in a "w" terminal.

Also, as i am short a functional brake servo, what are the prevailing thoughts on larger booster/master cylinder combos. Do any just bolt on, bleed and your away?

Pete Jones did a fair bit on brake upgrade. Non are exactly 'bolt on' but with a few minor mods a mk 3 booster and MC can be put in place of the orig setup.

I believe mk 2 16V booster fits straight on, but well, good luck finding one.

link in a tic to Pete's write up.

here it is:
http://www.vwwatercooled.org.au/newforum/upload/showthread.php?t=11689&highlight=brake+booster

[GoLfMan]

cool! Im also liking where this is going :)

will be interesting to see how the 1.6 goes turboed

[raiden]

this thing is going to be a little power rocket!

[mollins]

Im in Brunswick West. I'd love to catch up with some forum members, let me know when things are happening.

I will be living the diesel tachometer dream, first with a dedicated alternator driven tach, then by somehow driving a petrol tach with the alternator w terminal. Just gotta pull an alternator to bits to tap in a "w" terminal.

Also, as i am short a functional brake servo, what are the prevailing thoughts on larger booster/master cylinder combos. Do any just bolt on, bleed and your away?

Sounds like a great project mate! we need lots of these sorts of conversions! And much better to start with the 1.6 than the 1.5 for a turbo becasue the oil is fed onto the bottom of the pistons, which is important for cooling. But im sure you knew that!

I dunno if you saw my 1.9tdi mk1 conversion but i have done a fair bit of mucking around and reading, so if you have any questions then i hope i can help! http://www.vwdiesel.net/ is also a great resource

k14 is a great turbo for this too. Very fast spooling and boost all the way to the end of the rev range. The 1.9IDI mk3 runs this turbo as standard, and it is capable of running this at over 1.5 bar (22psi) without too much trouble.

Depending on your budget, consider ceramic coating the pistons (and maybe the head and valves). This keeps heat in the combustion chamber so it ends up through the turbo (producing boost) rather than the radiator. Intercooler is also a good idea, I am about to put one on my mk1 so i would be happy to share my setup ideas! (i will hopefully have it done this weekend).

Out of curiosity, Are you thinking about pointing the turbo manifold up or down?

For brakes, the easiest modification, which gives great results, is a SEAT cordoba booster and master cyl. Just requires some brake hose bending, and bleeding, and will easily handle bigger brakes (im running gti discs and mk3 drums). Make sure your vacuum pump is in good nick too.

hope this helps!

Now get to it!!
Cheers
Mike

[hiho]

Thanks Mike, im sure i'll need the assistance of forum members along the way.

The motor is at the machine shop, about to be hot tanked and crack tested. It doesnt have oil squirters. By accounts on vwdiesel.net and vortex this does not mean that it cant be turbocharged, but sense must prevail with regards to maximum output expectations. I will be using a TD pump which will help prevent overfueling off boost and will have a decent downpipe/exhaust, egt and boost gauges.

Does anyone know if intermediate shaft bearings are available for theses? (i assume its the same as the 1.5D)

Cheers

[gldgti]

yea you oughtnot have any trouble getting int shaft bearings - will be similar for all the diesel engines - 1.5/1.6/1.9...even 2.5..maybe.

cool project man! BTW -is yours solid lifter or hydraulic?

[hiho]

It has the mech head. This afternoon Im going to visit the machine shop for the measurements of the bores and crank. Then its a waiting game for the pistons and bearing to arrive. While im waiting i think i'll paint the block. Maybe mars red to match the car. Any thoughts on this very important decision?

[Jarred]

something other than black so you can see oil drips etc.

just imo anyways.

[hiho]

Are 200mm clutch/flywheels available in australia?

[Jarred]

I've never heard of 200mm clutch's. Heard of 210mm and 190mm though,.

[hiho]

I think the 1.6D and TD has a 200mm clutch as standard. Are 210mm clutch/flywheels available in australia?

[hiho]

The gearbox i have is a 4T code 020 which according to this table should have a 190mm clutch/flywheel. I just hope my 1.5D clutch fits up to the 1.6 Crank! Im on my way to the machine shop with clutch in hand to check.....

http://www.4crawler.com/Diesel/VW_020_transmission.shtml

[peedman]

Well if u need a 200mm clutch ive got one spare which is not needed. Bought it new thinking it was a 210mm one but unfortunately not. And yeh they only fit the mk2 diesels.

210mm is the mk2/3 petrol model which u can find pretty easily.

[hiho]

Time for a progress update.

Mostly it has been ordering/sourcing parts and building the motor.

This box from GAP contains ball joints, strut tops, coolant expansion tank with level sensor. I also have a set of engine mounts and urethane bushes from a previous order.
http://www.vwwatercooled.com.au/forums/images/imported/2009/07/IMG_2707s-1.jpg

And heres the motor internals, piston set, bearings, small end bushes, valves and oil pump. It doesnt look like much but this came to just under $1000! (including some gearbox goodies not pictured).
http://www.vwwatercooled.com.au/forums/images/imported/2009/07/IMG_2713s-1.jpg

The engine has been bored and will soon have the required machining work done to install oil squirters.

I have been busy at pickapart picking up rear drums, booster, mc and gearboxes with flywheel/clutch from Seats. I got a diesel style oil cooler too. My garage is full of greasy junk right now. I cant wait to start putting this all together!

[Water Boy]

Good work! Make sure all that greasy junk become nice clean parts before they go in :biggrin:

[hiho]

Some turbo candy...
http://www.vwwatercooled.com.au/forums/images/imported/2009/08/IMG_2738s-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2009/08/IMG_2741s-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2009/08/IMG_2742s-2.jpg
Its a k14 off a 1.6 or 1.9TD. I have a rebuild kit and will be stripping it this evening. Pics to follow....

In other news, I have a set of oil squirters that are going into the block
http://www.vwwatercooled.com.au/forums/images/imported/2009/08/IMG_2725r-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2009/08/IMG_2727-2.jpg

[16v_kid]

very nice work mate,

i got the same manifold...in pretty good condition.

pm if interested.

http://www.vwwatercooled.com.au/forums/images/imported/2009/04/P4091747-1.jpg

[hiho]

Room for a downpipe?
http://www.vwwatercooled.com.au/forums/images/imported/2009/08/IMG_2759s-2.jpg

Oil return line comes up a bit short....
http://www.vwwatercooled.com.au/forums/images/imported/2009/08/IMG_2761s-2.jpg

K14 comes apart
http://www.vwwatercooled.com.au/forums/images/imported/2009/08/IMG_2766s-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2009/08/IMG_2767s-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2009/08/IMG_2768s-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2009/08/IMG_2775s-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2009/08/IMG_2778s-2.jpg
Not much to a turbo, so far anyway. Still have to strip the bearing housing.

shaft play
http://www.vwwatercooled.com.au/forums/images/imported/2009/08/IMG_2771s-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2009/08/IMG_2772s-2.jpg
anyone care to suggest if this is acceptable for a bush style bearing turbo?

Next I'll be stripping the bearing housing and replacing the bearings and seals.... I think I'll have all the iron blasted to remove the rust too. More photos to follow.

[gldgti]

good work mate.

that much shaft play is probably almost normal (remember others looking at those pics that the k14 has a tiny little compressor wheel, much smaller than seen on petrol car turbo's).

as long as its sufficiently small that the wheel dosnt go near the housings when fitted and torqued properly, you're OK.

that oil return looks like the one for mounting the turbo in the "down" position (manifold flipped).

good stuff mate, nice when things are moving along :-)

[mollins]

good stuff mate.

The downpipe has to do a quick downwards U turn and then head straight down. We modified the linkage on my mk1 to give the downpipe a bit more space.

keep up the good work.

Mike

[hiho]

Thanks guys,

the turbo is off a 1.9TD which drains the oil back into the side of the block through a banjo fitting. I was hoping that it would reach one of the unused engine mount bolt holes in the block casting so i could simply drill and tap it for a banjo bolt but its too short. i should be able to have a longer section of braided hose fitted to it though.

I visited the motor on Saturday and was pleased to find a ceramic coating on my piston crowns and a friction coating on the skirts! Also, the cracks between the valves have been welded and new valve seats installed. Remaining is the installation of oil squirters, honing, and assembly of the block and grinding of the seats, skimming the head, installing the prechamber cups and assembly of the head!

Other bits that i need to sort out are:
Injector lines to clear the TD injector pump
Turbo oil supply
Bigger radiator
Downpipe for the k14
pre and inter plumbing
EGT, oil pressure and oil temp gauges
New injector nozzles
rebuilt injector pump
intercooler

And the car overall needs:
Rear swaybar fitted
suspension reinstalled
new ventilated discs
new DB401 pads
new front brake hoses
front sway bar
stereo capable of cutting through the clack
100mm inner cv joints fitted to the mk 1 axles

I have a cordoba booster, rear brakes and 22mm master cylinder ready to go, along with new Sachs dampers, king springs, rack ends, ball joints, urethane bushes and a toledo gearbox with 24mm input shaft and 210mm clutch

For the body i have gti flares, grill and a large new duckbill spoiler (which id gladly swap for a thin one). I also will fit an adjustable passenger side mirror that i have lying around.

[gldgti]

sounds like you've got all the bases covered mate, great stuff!



I also will fit an adjustable passenger side mirror that i have lying around.

i was dreaming about this the other day!!!!!! Im soooo jealous!

[hiho]

No more floppy side mirrors!

[49thdiver]

Great project, I am interested in the machining of the oil squirter ports.
I guess you have an ME block which did not have the ports drilled into the oil gallery. How did it go, did you have the machine shop do it or did you do it yourself. Did you use an old block to determine the location and angle or what ?

Do you really think the squirters were necessary given that you did the ceramic coating and don't plan to really push for high performance.

Peter

[peedman]

If your gonna get a new line you might as well put the return in the oil pan and get a bung welded up. That way u can also sell that oil return to me lol :rolleyes:

For injector nozzles i found this site a while back too:
http://www.veg-injection-service.com/store/index.php?main_page=index&cPath=6&zenid=5ae85c52c2ea40cf117ab791801744e8

[hiho]

Just cos i didnt plan for high performance doesnt mean that i wont try for it. I guess that i know myself!

[hiho]

A quick update on the project, the motor is home from the engine builder. It has the oil squirters installed. I have an intercooler from a saab, and a massive radiator from and Audi. Today I marked the toledo flywheel with a TDC mark and should have the motor and gearbox in this week! On the way from Canada I have a TD air filter assembly, CCV system and injector lines. All I need now is a k14 downpipe and exhaust.

Photos to come.....

[Oneofthegreats]

Hey Matt.

Thought I'd add this on here for reference sake & hopefully someone out there can also add some info.

I found the engine codes for the diesel engines in the US Spec caddy's for you

JK - 1985-90
ME - 1990-92

Rod bolt # 037 105 425
Rod nut # 068 105 427

This is the bit of info I'm not 100% on though sorry Matt.

The tightening torque of the conrod nuts (the conrod's have pressed in rod bolts & then the nuts are tightened as below)

33 ft lbs - NA form for the engine code above.


For the turbo'd diesel (AAZ) They are conrod bolts

depending on chassis # or bolt size

028 105 425G M8x1x42
028 105 425C M8x1x45

22 ft lbs +1/4 turn is - FI/Turbo (stretch bolts)

[hiho]

Fitted 2.5" mandrel bent exhaust and tidied up engine bay. It wont be long now and there will be white smoke at the front, black at the back!

[hiho]

Donor motor, 1.6D
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/IMG_52501-2.jpg

Long motor ready
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/Image029-2.jpg

Engine build bits inc turbo pistons, valves and oil pump
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/IMG_2712s1-2.jpg

Thermal/friction coated pistons
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/IMG_2827s-2.jpg

Motor is in!
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/IMG_3267s-2.jpg

Cylinder head with new seats and guides
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/IMG_2828-2.jpg

mild porting
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/IMG_2829-2.jpg

[Dub Toffee]

WOW nice work!!! I admire your bravery!!
hope you get a great sense of satisfaction at the end of this one :-)

[hiho]

Coated pistons
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/IMG_2827s-2.jpg

Block to be honed
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/IMG_2833s-2.jpg

Engine bay bits
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/IMG_3266s-2.jpg

Oil squirters installed in the block
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/Image026-2.jpg

[Jarred]

good work, glad to see it's coming together!

[Golf Loon]

Looking Good Mate. Nice to see a build thread with some action and pics.
Keep the updates coming.