Project Turbodiesel

[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.


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).


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

[hiho]

Some turbo candy...



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

[16v_kid]

very nice work mate,

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

pm if interested.

[hiho]

Room for a downpipe?


Oil return line comes up a bit short....


K14 comes apart





Not much to a turbo, so far anyway. Still have to strip the bearing housing.

shaft play


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]

Oil squirters

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

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