The mk3 1.9L TD power-quest

[Preen59]

Sounds great, dude!

[gldgti]

Happy plumbing matey....

too true

[Jarred]

:O

NICE! can't wait for this!

[gldgti]

hey diesel heads - heres a little heads up update -

after a bit of a gearbox saga, I will this weekend be doing an 02a conversion to an ASD code gearbox (mk3 TDI box, longest ratios they made. 2500rpm at 120km/h on 195/50/15's). No more 020 for me

[gldgti]

Massive weekend, but its in and running! woot for 228mm clutch!

[Jarred]

nice, good work!

did you convert the 02a to rod shift or install the cabkes shift mech?

[gldgti]

nope, full conversion. everything 020 gone, everything 02a in. That means clutch pedal and brackets, hydraulic line, cable shift shifter box (pull off exhaust and heat shields, uuurgh), front engine mount, starter, lenghtn wiring looms for reverse switch and speedo... etc etc etc. I guess its not a huge deal really, but when your working by yourself, it felt like a lot for 1 weekend, hehe.

[gldgti]

little update - i've done 1200km's on the new setup and not a single hiccup, leak, drip or crunch. something must be really wrong, 'cos nothings gone wrong yet

tonight I was driving to pick up my fiance as usual, and I realised all this time nursing around the car with a slipping clutch or other similar worries, i've turned myself into such a softy. so i gave it the beans for the rest of the trip home and the car really seemed to love it

[gldgti]

Update

Little update here...
Remember way back when I installed the larger T3? Well, after trying out the standard 1.6VW T3 (about 8 months) and the kkk k14 (about 3 months) I finally got around to fixing up the waste gate on my Mercedes spec bigger T3.... initially I had it in the car with the waste gate valve locked closed, so I really had to baby it around and never got a proper feel for how it could go - I only really figured out that it flowed well and could fly way past 25psi...!

On Saturday afternoon I swapped it back in with newly customized and modified waste gate actuator (made more compact, as before it hit the firewall - its tight back there with such a big turbo) set at a stately and safe 15psi. Now that I can give it the full pedal up to the high revs.... wow!

Its quite a different car, and just to stop typing words, I think I might even be happy enough to go try and get it dyno'd in the next couple of weeks to really see what its doing

[Preen59]

Great work, Aydan. Cool as mate!

[Greg Roles]

So what did it run stock, and I wonder what would blow up first if you pushed it?

Funny how long you put up with stuff mid tinker, I still haven't run my water meth I bought in Feb!!

[gldgti]

The stock turbo was a T2. I ran that up to 22psi, but stock boost was 12psi.

The AAZ is pretty good for 30-35psi if done right (nice inlet manifold for flow distribution etc) but if done badly the first thing to go is either headgasket (ARP studs fix that) or maybe a bent conrod.

I'm going to crank it up to 22ish psi this afternoon. The main thing that worries me with this turbo is surge at lower rpm, as it seems to be capable (if i push it) of making large boost at low rpm, I dont want to snap the shaft.

[Jarred]

Cool as!

It'd be really interesting to see some numbers!

[gldgti]

Dyno tomorrow arvo.

[gldgti]

FAIL!!!!

You wouldn't read about it - I have to drive maybe 800m to the dyno place from my work, and as I turned out of our complex driveway, car starts making a funny noise and i discover that the brass bushing that the wastegate actuator rod passes though has popped out of the exhaust housing!

I will attempt to fix tonight, and if I can't, it'll be atleast a week or so I reckon 'cos my weekend is full up!



sorry guys