The mk3 1.9L TD power-quest

[gldgti]

i'll be there mate - nice and early and parked inside. entering the car in mk3 modified...

hope everyone else is going too!

[GoLfMan]

sweet cya sunday!

[mollins]

gregozedobe,

i dont think i need a bigger clutch, theres a good chance mine is original and the car's at 160,000km but its not slippy normally, so its probably just getting close to worn. i would say that a new clutch will fix that problem (which hasnt yet reoccurred... yet) and i have one in a box downstairs.

me thinks you need to fix your clutch soon.. it slipped when i floored it in 3rd gear on sunday!

maybe next weekend we should swap it?... or do some more to the mk1.. hmmm.. too many vws.. not enough time

[gldgti]

so on friday night i got back on the injector pump with my 13mm spanner, torx set and screwdriver and did a bit of tweaking.

i backed off the fuel screw a bit (yes, backed off) so that LESS fuel is going in generally. I also changed the limit switch position for the electronic wastegating to a little further along the throttle range, so that the turbo doesnt spool when im cruising at 110km/h. this means that theres no boost pressure acting on the LDA, and no extra fuel going in, so theoretically better economy. im pretty confident it will work.

i also adjusted the position of the boost compensator pin a little.

i seem to have about the same amount of power as before, but hardly any smoke at all. i've got the turbo spooling to 17psi now at peak boost, and it really pulls well, but now theres only ever any smoke at full throttle, just before boost comes on (say 3rd gear, 45km/h, foot flat). apart from that, its crystal clear out the back window!

im liking this a lot - it feels cleaner. haha. anyway, im hoping i will get a bit better economy now. im keen to break the 5l/100km mark and show all you TDI guys that you can do it the luddite way aswell

[Preen59]

so on friday night i got back on the injector pump with my 13mm spanner, torx set and screwdriver and did a bit of tweaking.

i backed off the fuel screw a bit (yes, backed off) so that LESS fuel is going in generally. I also changed the limit switch position for the electronic wastegating to a little further along the throttle range, so that the turbo doesnt spool when im cruising at 110km/h. this means that theres no boost pressure acting on the LDA, and no extra fuel going in, so theoretically better economy. im pretty confident it will work.

i also adjusted the position of the boost compensator pin a little.

i seem to have about the same amount of power as before, but hardly any smoke at all. i've got the turbo spooling to 17psi now at peak boost, and it really pulls well, but now theres only ever any smoke at full throttle, just before boost comes on (say 3rd gear, 45km/h, foot flat). apart from that, its crystal clear out the back window!

im liking this a lot - it feels cleaner. haha. anyway, im hoping i will get a bit better economy now. im keen to break the 5l/100km mark and show all you TDI guys that you can do it the luddite way aswell

Nice work man. I love to see some real tuning going on. Hard to find anymore. Most people are like "It's a little rich but i don't have my laptop with me" these days.

Go old school tuning by feel!

[GoLfMan]

good on ya Aydan, love ya style and the fact your not scared to get in there and do it yourself

[gldgti]

turbo death

hi again guys,

well not sure bit i think i might be killing my turbo....

i'm getting a bit more whistle than i used to and apart from that my exhaust smells oily, so i reckon i'm leaking a bit of oil from the turbo into the intake.... might have a looky at the intercooler on the weekend, i suspect its filling up with oil ha.

so, i guess its time soon for a k04!

[Jarred]

maybe you've just done the seals...?

silver lining to every cloud...

[Greg Roles]

hi again guys,

well not sure bit i think i might be killing my turbo....

i'm getting a bit more whistle than i used to and apart from that my exhaust smells oily, so i reckon i'm leaking a bit of oil from the turbo into the intake.... might have a looky at the intercooler on the weekend, i suspect its filling up with oil ha.

so, i guess its time soon for a k04!

Sorry to hear that..but I would have thought the main point of oil ingress into your inlet would be through the crank case venting. Sure all total loss turbo bearings leak oil into the inlet / exhaust a little, but my money is on the extra boost getting past the rings and causing extra pressure in your sump, and thus more oil and vapour coming out the vent. I'm only at 9000kms now, and I've dumped a good 200mL plus of oil from the bottom of my provent oil vapour filter doobie, so you can just imagine what a few hundred k's does for an inlet oil wise!

I'd be looking at the oil film before, and after the point at which the vent system enters the inlet. I know TDI-club goes on and on about cleaning intercoolers and the amount of oil ingress through the vent system.

Good luck, and I hope it's not the turbo seals!

[gldgti]

Good luck, and I hope it's not the turbo seals!

im secretly hoping it is...

the breather is a good point, maybe i should put in a catch can and see what happens... the thing is that the breather assembly has a cyclic separator to prevent that from happenning on the AAZ, so i'm doubtful.

we shall see.

[Greg Roles]

My man, the current TDI has no less than 5 oil seperation systems, including a cyclic of amazing design, and the whole thing takes up several pages in the study manual. It amazed me with it's complexity, and yet my provent is collecting a suprising amount of oil. In the first 9000k, with new car tolerances I've collected a few hundred mL. Certainly a lot more than you would like to have going through your intake, especially when it combines with the EGR circuit and mixes to make sludge.

My bet is this is the majority of your delimma.

[gldgti]

My man, the current TDI has no less than 5 oil seperation systems, including a cyclic of amazing design, and the whole thing takes up several pages in the study manual. It amazed me with it's complexity, and yet my provent is collecting a suprising amount of oil. In the first 9000k, with new car tolerances I've collected a few hundred mL. Certainly a lot more than you would like to have going through your intake, especially when it combines with the EGR circuit and mixes to make sludge.

My bet is this is the majority of your delimma.

well you convinced me.... what did you buy to fix it?

[Greg Roles]

I bought a Provent oil catch system from Mann and Hummell ( Aust ) in Sydney. It was rather dear at $200 plus post, but a very nice unit, and well designed. I'm sure a simple oil catch can, sealed, and reconnected into the inlet vacuum would be just as good, but at the time I had been messing with a few half arsed designs and got sick of oil everywhere so just bought it despite the hefty price tag.

Post #2.

http://www.vwwatercooled.org.au/newf...ad.php?t=13929

Here's how to make one from the awesome website Autospeed. I figure that's the ticket for you Mr Tinkerer !

http://www.autospeed.com.au/cms/A_1576/article.html

[smithy010]

That one on the autospeed website should be a doddle for you Aydan!

It's very nice.

[gldgti]

i smell an after work project coming on....