Rolling with Pebbles

[twin eng, twin turbs]

That turbo is a cutie! Its a T2 and will boost up very quick but run out of flow at high rpms. Probably a good choice if you want drivabilty and instant boost.

[hiho]

Pebbles is now rolling with 5 speeds. Scored a cordoba gearbox with the right ratios, complete with flywheel and clutch. If anyone wants to do this swap, you will need to fab/source a gearbox mount, grab the 15 tooth (usually red) speedo drive gear (just pull it off the end of the cable) and the sandwich plate and covers. Also, either swap the 100mm drive shaft flanges for a set of 90mm flanges or else, mod your drive shafts to accept the 100mm inner cv joints off the cordoba (they are thicker than the 90mm cv joints so the shoulder on the mk1 drive shaft needs to have the difference machined off it). I had a set of 90mm flanges so i swapped them and replaced the seals while i was at it.

[hiho]

Oh, also, the cordoba flywheel doesnt have a TDC mark to suit the diesel. PITA

[gldgti]

hey mate,
i reckon that turbo would be alright for a 1.5 - you wont be able to run too much boost anyway - but i thought you had a 1.6 with k14? or is that your other project?

either way, the t2 on the 1.5 will certainly be a viable option - most important thing will bne to run a decent intercooler setup and some head studs.

you can get an aftermarket vw 8V turbo exhaust manifold from ebay that suits the t3 bolt pattern - i'm not sure how different it is from the one you have there, but i reckon would be a good start

[hiho]

thanks Ayden, Im going to see if the ebay vendors of 8v T2 turbo manifolds will ship one for less than $144, then it might be a great deal!
The k14 is for the 1.6TD build which is progressing slowly, oil squirters just arrived from Canada.

[hiho]

Last week the exhaust pipe broke just in front of the rear muffler. I liked the sound and the performance gain but Leah didnt. I decided to compromise and had a 2" pipe installed with a new 2" flexible join at the front. The car is pleasant again and really likes to rev! Big improvement

[gldgti]

yes indeed, i found that my old 1.5 went much better after a bigger exhaust was put on - really opened up the upper rev range. best i got it was with a genuine GTi exhaust (front half, with 2 pipes to the shifter box) and 2" from there back. was a bit noisy though

[RhysQ]

Just had a read through this thread.... awesome work you are doing with the car to get it back to it's former glory (and more by the sounds of it). Will be watching this thread closely.

Best of luck mate,
Rhys

[hiho]

a split heater hose threatened to kill Pebbles last night. Im driving her 1000kms/week on average (and loving it!). On the way to Mt Beauty (where I've been working) I noticed the temp a bit high and the thermo fan light didnt come on. Having lost a rebuilt diesel to a split hose I watch the temp like a hawk. I pulled over and yep, coolant leaking out from the hose that connects the head to the water pump. This is the same hose that killed Hiho. (gimme a break, my girlfriend only lets me have old cars if she can name them). I got towed to benalla, stayed in a nice hotel and hacked a subaru leone top radiator hose to bits to make a replacement. Filled with antifreeze and was away!

Lesson 1 - connect a dashboard light to the radiator fan thermo switch that tells you when the fan is on. Better still, add a relay while you're at it (mmm relays.....)
Lesson 2 - if the temp is high and the radiator fan isnt on, pull over! You may have lost coolant, a stuck thermostat or a bung thermo switch. The former will kill your diesel VERY QUICKLY - overheating cracks the block on 1.5 diesels
Lesson 3 - diesel fuel attacks rubber. The hose that failed is directly under the injector pump. When adjusting/priming etc, always wash the diesel off the motor, with particular attention to the hoses at the rear of the water pump!
Lesson 4 - Girls love old cars so much they cant help but name them

[Jarred]

hahah

Good to hear it's still kicking!

nothing a bit of road side inginuity can't fix!

[hiho]

Pebbles got turbo'd. Our daily driver is a 1.6TD! That is until my girl gets home tonight in her shiny new reliable quiet safe clean rust free red 2009 Polo TDI. Then it becomes a true project car!

I installed a factory TD motor and gearbox that I pinched from a car I brought over from adelaide late last year. It has been a bit of a headache since installing it and the long felt feeling of reliability disappeared....






It doesnt start on cold mornings without a little help. I suspect a thicker than required head gasket has been installed..... Or the timing is off

THe flywheel has no TDC mark. I cant check the cam or injector timing......

Lots of minor water leaks

Huge gearbox oil leak.... Mangled seal carrier

New seal carrier installed

New seal installed

Flange going back on


I'll replace this box with an AMC Toledo box in a couple of weekends. It has the larger input shaft, 210mm clutch and 100mm flanges. Should be good for whatever i squeeze from the TD

I also got paranoid about the intermediate shaft bearing. The bearing usually never wears out on a petrol motor. But with the IP and cam to drive, and with some people overtightening the belt due to concern of piston/valve contact due to a skipped tooth, the bearing at the pulley end can wear prematurely in a diesel. I believe that it should be inspected when changing the timing belt. Mine was ok so i didnt replace it. Apparently you can tap the old one sideways with a punch (put a rag in there to catch it so it doesnt end up in the sump) and remove it then install the new bearing using the intermediate shaft as a guide.

With the new flywheel (complete with TDC marking), egt gauge and 2.5" exhaust I should be able to start tuning!!!

[gldgti]

show us yer exhaust!

[Preen59]

Nice work.

Just advance the injector timing dude. It won't hurt.

[hiho]

2.5 is the rusty sections top left

I am not worried about the ip timing so much as the cam timing. When i swap the gearbox i'll fit a 210mm flywheel with a TDC mark on it!

[gldgti]

hehe, i spy a turbo outlet flange with a bit of 2.5" pipe on it.

have you been driving it around with no exhaust?