98 Jetta TDI

[VWTUNING]

What do these normally go for? What are they rated at power wise and how easy is it to get more out of them? Cost/Ease of mods? Brent found one on craigslist and im thinking of picking it up for a daily.

TIA.

[BUNNYLOVE]

Ha, I emailed about this one too. They normally go for 4-6K depending on condition. Junkers or wrecked ones go for $2500-3. This one looks a little rough but its most likely worth it.

They have 90hp and 150 Lb/ft stock. Basic mods like nozzles are $200-300, chip tuning is $300ish. That will give you probably 120hp and 250 Lb/ft. Beyond that it gets expensive with turbo upgrades, pumps, intercoolers, etc.

[VWTUNING]

I bet he got lots of emails at that price :laugh:

250ft/lbs you say :eek:

[BUNNYLOVE]

Yeah, if its not gone already I would be really suprised. 250 lb/ft is not tough to get.. its usually under 2000rpms too.

[FusLit]

Well, did either of you buy it :)

-Todd

[VWTUNING]

I got no email back yet :(


kinda thinking it sold...

[OnelowcabriO]

it was posted at 11:11 pm lastnight, i emailed him at 8:30 am this morning, and havent gotten anything back yet either, im sure he will have about 50 emails waiting for him when he gets home :laugh:

[BUNNYLOVE]

Hmmm your a few hours quicker than me. I bet neither of us are near first in line though.

[FusLit]

he has no one to blame but himself (if I were him I'd sell your e-mails to a spam list to make up the loss he's gonna take...)

Kidding


-Todd

maybe

[boostin20v]

he has no one to blame but himself (if I were him I'd sell your e-mails to a spam list to make up the loss he's gonna take...)


LOL :laugh:

[VWTUNING]

Went to look at it on lunch, guy wasnt there but he left the key for me. Potentially going to meet him at 3PM to give him a downpayment. Heres some pics, let me know what y'all think!

http://uploader.ws/upload/200805/DSC00050_Medium.jpg
http://uploader.ws/upload/200805/DSC00051_Medium.jpg
http://uploader.ws/upload/200805/DSC00052_Medium.jpg
http://uploader.ws/upload/200805/DSC00053_Medium.jpg
http://uploader.ws/upload/200805/DSC00054_Medium.jpg
http://uploader.ws/upload/200805/DSC00055_Medium.jpg
http://uploader.ws/upload/200805/DSC00056_Medium.jpg
http://uploader.ws/upload/200805/DSC00058_Medium.jpg
http://uploader.ws/upload/200805/DSC00059_Medium.jpg

[FlyBy]

that thing is sooo beat between the interior and all that rust on the outside of the car. It's pretty beat for a 98, and it's well over 200K miles.

Do you really want it that bad?

[useanimagination]

is it green or black?

[BUNNYLOVE]

A new vc gasket and degreaser would do wonders. The VC comes of with three nuts too.

[VWTUNING]

Is that rust colored crap around the coolant bubble anything to worry about? I think I've seen something similar on a car with a blown head gasket. But I started it up and looked around the engine and saw no signs of a leaky head gasket.

[FusLit]

if it's structurally sound (i.e. strut towers good shape, brakes stop, etc)

You could always buy a cheap shell and swap things across..

you'll be hard pressed to find one cheaper, closer, with all the bits you need.

I say go for it.

-todd

[VWTUNING]

thats exactly what im thinking Toddman. I have always fancied a Tdi MK2...

[BUNNYLOVE]

def drive it until it hits full temp. Your gonna need to go on the hwy. he said the rad is weeping so it might be full of water..

[iceVee]

If I'd known this thing was right around the corner from me I could have checked it out for you :smile:

Looks like a most excellent drive-it-cheap-fun beater!

[stephan315]

Come on Pete, If you keep getting these projects the rabbit's never gonna get finished... i guess you'll just have to sell her to me... the rabbit that is...

[vwremglx]

I have always fancied a Tdi MK2...

w00t!!

[iceVee]

I'd like to be the first to say...




Lower it!


:laugh:

[USOPHUNKE]

it looks kinda eat, ut if it runs smooth and shifts fine would make a great swap engine. you would have everything...

the coolant bottle orange...I would ask him if it ever had a head gasket go... doughtful but ya never know

lower it x2

[Brightdub]

Too bad you want a tdi, I just got rid of my 99 wolfsburg jetta for only 2 grand a couple weeks ago, it was almost perfect besides a dent that had to be pulled out, it had brand new everything including the clutch.... and it had 95k on the clock took me like 5 months to sell it... and I finally took the loss and got 2000 for it when it was worth well over 5.... how much is that guy asking for that 200k plus tdi?

[meatwad!!]

how much is this?

theres 2 mk3s in the swap sheet that would be good to pick up with this if they are clean. swap and part out!

[allstarrme]

yeah, how much pete? I have a perfect MK2 shell and a 5 lug setup for it. let me know, because I will give you a finders fee if you don't take it. that looks like a headgasket issue with oil in the coolant.

[VWTUNING]

So I got a call today from a friend who knows some history on this car, he tells me:


1. tubro is shot and needs to be replaced. It makes boost but is leaking into the exhaust.

2. N75 valve needs to be replaced, keeps going into limp mode.

3. Timing belt was replaced, but supplied tenisoner was wrong so its got the original tensioner back on there. Also water pump was not done at the same time.

4. CEL is blown/removed.

5. Veggie oil setup was ghetto and he was not running 'very refined' stuff.

6. suspected blow by cause it has no power. at the same time it sounds like the intake and EGR is full. It was not cleaned cause they couldnt get the manifold off.

7. Head gasket has been replaced at soem point but doesnt know details.


Thats the jist of it. I'm gonna BS the guy a bit and see if I can get it cheap, otherwise considering passing on it... but at the same time I still think its a good deal, even if it needs work.

[BUNNYLOVE]

yeah the low power could be the intake/egr for sure. At 250K its probably completely blocked if its never been cleaned. Also it could be hitting limp for many reasons besides the N75 itself. There is a little vac. hose in the ecu that goes bad for example.
Its just gonna need alot of tinkering to get it right.

[VWTUNING]

Well I'm sure I'll get to the bottom of it with all youz guyz help :P I offered him $2000 and he accepted. I pick it up at 6:30PM!


<----- Extremely excited to tinker with a diesel :icon_cool:

[BUNNYLOVE]

Woot! Let me know if you need any help...except cleaning. Diesely grease is nasty..stains your skin.

[FusLit]

congrats man

you suck :laugh:

-todd

[MKIIIGOLFGTI]

congrats pete!

ps limp mode could also be from the dv.

[rabbitgtdguy]

Congrats...and nice find...even if only to rebuild and have for a complete swap. You'll def. want to head after that intake first...get it unclogged. Tackle turbo and alot of weeping is coming from the elephant hose that attaches to the CCV puck...they are known to deform/crack.

Let me know if you need an help. I'm well versed with these engines and am building another at the moment.

Joe

[reverendhorton]

congrats pete! I'm glad you went for it because I look forward to seeing what you can do with it..

[evolveVW]

Hopefully he didn't run the veggie oil for long then. He could have really gunked the injectors and pump, especially at that high mileage. It also could have contributed to turbo failure, CEL, and intake clogging. Poorly prepared WVO causes sky high EGTs and poor fuel burn. Todd probably has a turbo laying around for it, I forget if these have the KKK or T series turbos in them.

[USOPHUNKE]

cool..go big turbo.....

glad you got it, good luck.. I will get some pure alcohal and dielectric cleaner from work.. you are going to need it

[rabbitgtdguy]

Original turbo should be a K03 or a T15.... :( Def. room for improvement! I'd def. do some testing of the motor before going nuts though...especially without a rebuild... :)

Joe

[kabinotar]

Pete! That's so awesome. I've always wanted a mk3 tdi. :smile:

[stephan315]

so you've got VR6 covered, 2.0 covered, 20v started, and now TDI.... By the time you finish you will have everyone covered for everything they need... I always knew you were the VW man... atleast with the help of the Fastdub/Dubspot crews... ;)


congrats on the purchase...
Like I said earlier... I'll take the rabbit off your hands now...

[meatwad!!]

if its a k03.. i has one you can have.

[RichB]

From what Pete told me it looks like the owner was running a mix of veg oil, Kerosone, Cetane booster and some other stuff... smells like french fries!!! :laugh:

Looks like its going to be a fun project car Pete!

[Master_Shake]

i missed the smoke. but the car looks like it'll be fun.

[lotar_6]

f'n congrat's Pete! HOw many cars does this make now? How many combined inches off the ground?


i'm gonna crash now.

[Jackalope]

IMO...install FF fryer at Dubspot...

[orion2.0]

careful mang! running WVO even with pre-heating in tdi's kills the injector pumps (a very expensive part). Its not such a big problem with the older pre-direct injection diesels.

I would beat on the car for a couple years...then rebuild the motor and put it in another car. Good buy! Its worth it just for the engine.

[evolveVW]

I just saw an ALH engine and trans with 86k selling for 3250 on tdiclub...so yeah even with the issues the engine is worth what you paid Pete

[MKIIIGOLFGTI]

Not to mention the smoke from it chases the skeeters away!

[KPz]

Found a huge gash in a coupler, replaced it and it made a huge difference in power! lm ****ing stoked! the code for the boost control valve went away too, guessing the rip was the problem all along.

what does it mean when the glow plug light starts flashing after the car is running?? it did that for awhile after I cleaned up the bay. Hopefully just a fluke from getting wet.

P.S. is 18-20 psi normal/stock? seems high!

p.p.s. the smoke it makes is the coolest thing ever :icon_cool:


-Pete

[iceVee]

what does it mean when the glow plug light starts flashing after the car is running?? it did that for awhile after I cleaned up the bay. Hopefully just a fluke from getting wet.
-Pete

Water in the fuel. Seems odd you'd get that light unless you got water into the fuel system somehow.

If you did:

On the Mk2s there's a water separator drain under the car at the tank, plus the water sep filter under the hood. Dunno about Mk3s...

[evolveVW]

Usually it means a fault in the glow plug system... resistance difference between glow plugs, wiring short to ground, bad relay.

[USOPHUNKE]

i saw car running tonight, not to smokey and it did smoke when the turbo made a wierd chatter sound... never heard a turbo do that before.... I wonder if the fins are touching or its getting a ton of blow by... great deal and pick up for sure!!!

[iceVee]

Usually it means a fault in the glow plug system... resistance difference between glow plugs, wiring short to ground, bad relay.

The only info I have is for Mk2s - owner's manual and the Bentley. They both mention water in the fuel if the light blinks, but there is nothing about glow plug system faults. The TDIs get a more sophisticated system I guess? A glow plug ish indication makes more sense than water in the fuel if it's blinking immediately after an engine bay bath...

[evolveVW]

yeah the TDIs are much more sophisticated.

[evolveVW]

here's a turbo for sale for cheap, trying to find out if it is the correct one

http://forums.vwvortex.com/zeropost?cmd=tshow&id=3864817

Never mind, its a VNT from a Mk4. You should find a cheap front mount setup, get some nozzles and software and put a small T3 on it :D

[VWTUNING]

once things dried out the glow plug light stopped coming on. I think the engine was freaking out cause its never been cleaned :laugh:

after i fixed the coupler the car seemed to re-adapt and 'lean' it self out. so its not smoking near what it was when i first fixed the problem. i am getting an occasional chatter when getting on it, like brent heard when reving it after parking. and there is oil dripping from the center section. Rob is giving me a K03 which I will be swapping on if I cant fix the leak.

I am loving the torque the oil pan clearance... i gotta admit its got the wheels turning.

[wolfs99]

Pete time to change your signature !

[evolveVW]

sounds like that turbo is pretty much done for.. major shaft play probably

[VWTUNING]

yeah i got soem investigating to do, gonna pull the intake to clean and check turbo out. found a ton of good info here :icon_tup:


http://www.tdiclub.com/TDIFAQ/



thanks everyone for the feeedback and help :)

[evolveVW]

the TDIclub FAQ rules!!! Ive used it a lot.

[BUNNYLOVE]

The 1.8t Ko3 is a different turbo, they are not compatible. Sucks since they are everywhere and cheap. Don't buy a turbo off ebay, they do not fit right..chinese. Your best bet is just buying a new oem Ko3, they are about $500 brand new. Or finding a used one.. but finding a good one is tough.

Beware with sketchy turbos...if it goes your engine can runaway since it will run on engine oil. Even if you turn the ignition off it can rev to the moon and blow up.

[VWTUNING]

I was under the impresion I could swap the exhaust housings to make a 1.8T turbo work. But I have zero experience with this so im running on hear-say. I dont mind spending $500 on a new turbo if it comes down to it, but first thing im gonna do is tear the intake off to clean and while thats out I'll be inspecting the turbo.


For the coupler I need (the one between the intake manifold and the hard plastic charge pipe) should I just get it from the dealer? Or make my own with a generic coupler? The radiator hose Im using is holding up OK for now, but the way it inflates I know its just a matter of time before it pops :laugh:

[BUNNYLOVE]

The center section *might* swap but I doubt it. The turbine and comp. housing are both different. I'm guessing the 1.8T has a larger ex. wheel atleast.

I would check on the dealer part first, I heard the oem couplers are pricey though. Any boost leak will make it smoke. Boost makes the smoke go away, so if its slow to spool from a boost leak you'll get smoke until you build enough boost to clear it.

[VWTUNING]

Ryan - when you replaced your turbo, did you just get a stock replacement or did you upgrade at all?

Also - can I run nozzles with out a tune? Or do I need that to match the nozzles I get? What setup were you running in the beetle?

Do diesels respond well to opening up the exhaust? (I would assume so but me = n00b). I'm looking at 2.5" DP back.

[BUNNYLOVE]

I didn't but only because there aren't really good upgrades out yet. I was going to to the GT2052 but I decided not too since I don't want any lag in my truck. I made a manifold and everything.. I bought the chinese one on ebay and although it has worked fine, it doesn't fit quite right and need much dicking with to get it working right. The only option out right now is a K04 hybrid thats like $900 and is barely an upgrade IMO.

You can run nozzles only without a tune, I'm running PP764s in my truck with no tune. I have very little smoke too. You might have more smoke though... you can adjust it a little with the vag com and usually get it under control.

Exhaust, yeah a 2.5" turbo back would be good. You don't need a muffler especially if you keep the cat. Most people just chop of the muffler and leave it though. You'll see bigger gains after you have more stuff done.

[turbosnow]

cool pete, glad you got a TDI...woot!
TDI stuff is one of the few things that are cheap over here due to abundance so if you need anything let me know...

[evolveVW]

Like Ryan said, big exhaust doesn't do anything until you start going big. Just chop the mufflers out and call it a day. It has as much to do with EGTs as flow. A lot of guys are going to a GT1852, but they still can be pricey.

[VWTUNING]

most of it is rusting away Vin, so im thinking a cheap 2.5" setup with no mufflers will do good.

KermaTDI offers rebuilt hybrid turbos for ~$900, same price Ryan mentioned replacement turbos go fo. I figure if I have to replace, why not upgrade!


Ryan - What do the numbers mean on the nozzle ratings. I see they some times have the same number and call one MILD and another WILD. If they are the same number I dont get it. I must be over looking something.


How did you choose those nozzles? And do you have a tune with them? Sorry for the n00b questions, im trying to read as much as possible so I dont bother you guys :P

[Jackalope]

most of it is rusting away Vin, so im thinking a cheap 2.5" setup with no mufflers will do good.



Five finger discount a 2.5" off a certain MK5 that's low n slow with green BBS's??? Just a thought? Maybe the owner of that 'special' car would part with it? Not sure if it would work for the TDi, but hey...you want cheap and maybe he wants a nicer exhaust? Putting MK5 parts on it will bring up the resale value....:laugh:

[evolveVW]

Like Sprint520s and PP520s? The Sprints are the same (.205) as the Euro 110hp TDIs, while the PP520s are the same orifice size (.205) but are optimized for flow and more power. The PP764s are larger than the PP520s, and the PP502s are even bigger. Then you get into the RACE nozzles, which are huge orifice nozzles.

[BUNNYLOVE]

A stock replacement turbo is ~$500 brand new. Although I just looked and couldn't find one for under $650..

The sizes are kinda tough to follow. Sprints are the more budget nozzles, the PP (performance plus IIRC) is the performance line. PP520s seem to be the most popular. With the stock turbo anything more than PP764 is probably going to be too much.

[MKIIIGOLFGTI]

pete maybe you could snag the exhaust off that blue jetta behind the shop.

[evolveVW]

I was thinking today... I did not notice a secondary fuel system for the WVO when I was under the hood last night, meaning the PO dumped the stuff straight into the tank, exposing the IP, nozzles etc to fluid 11 times thicker than diesel because it was not heated. I would get some high quality (LubriMoly makes one) diesel fuel system cleaner and run it through soon, and replace the fuel filter. I am surprised that the thing still runs...

[FusLit]

Vin: I was talking with Pete about what the PO ran through it and it was a combination of kero, cetane booster and wvo filtered through a 2 micron filter.

So it's not a dire as running straight wvo, but as you say, not a bad idea to run the cleaner and filter change...

-Todd

[VWTUNING]

Yeah he was 'processing' it and yes running it right in the tank. For the last 50K he claims (except during the winter he ran regular diesel) . Todd I was wrong it wasnt 2 micron it was 20, not sure if that is much worse :icon_confused:

Here is the recipe he gave me:

5 gallons of veggie oil.

1 gallon kerosene.

1 quart of gasoline.

1/2 cup of cetane boost.

mix well, then pump thru a whole house filter using a 20 micron settlement cartridge right into the tank. The filter housing is around $20, its light blue in color, with a red pressure relief button on the very top. The 20 micron filter cartridges come in 2 packs, and are about $5 for a 2 pack.


Car currently has the stuff in the tank and seems to run fine. I'm curious to see how things look once i get the manifold off and can peak in the head. I saw that cleaner you're talking about Vin and will likely run the treatment, but my priority for the time being is just to get it up and running mechanically solid first. I am really excited to dig in :smile:

[BUNNYLOVE]

Wow thats interesting, ghetto biodiesel LOL. Not heated at all huh?

That cleaner, diesel purge is really good. Run it directly though the pump.. or you can do 1/2 in the pump 1/2 in the tank.

[evolveVW]

20 microns is way too big. Acceptable filter size is usually 5 microns.

Thanks Ryan, I couldn't remember the name. Another thing guys do with it is fill the fuel filter with it when theyput a new filter in.

[VWTUNING]

Turbo appears to be fine, very little to no shaft play. All the oil appears to be coming from the feed line which is patched with rubber line.

EGR has what appears to be jb weld on it, where some one was trying to cut a bolt head off. Can I jsut elliminate it all? Some of the bolts are really bad, would be nice just to be able to cut it off and block it off.

p.s. the EGR-to-water cooler is friggin cool!

[B4passatglx]

Good news about the turbo being good. That seems to be one of the more expensive parts to have to rebuild/replace

I don't know jack about diesels though.

Start a build thread on it!

[97GLSsleeper]

- EGR Removed - Check
- Intake manifold removed - Check
- All stripped and beat up nuts and bolts removed - Check
- Crappy rubber hose oil return line removed - Check
- Intake manifold sitting in parts cleaner getting cleaned - Check

All in all a good night. We got a lot done and this TDI is soon to be a real beast.

[BUNNYLOVE]

How did you remove the EGR? Its integrated with intake manifold just removing it can really happen. Are you guys talking about the EGR tube?

You can remove the egr cooler, the tubes and everything. You might get a CEL every once in a while but it doesn't actually hurt anything. My truck is like this. You can get the EGR electronically removed if you get a custom chip too.

[97GLSsleeper]

You're right we actually just took off the cooler and tubing, but we were talking about cutting down the manifold and cutsom making something so we could actually remove the EGR itself. We werent really sure if it could be done or not, but we were tossing around ideas.

[evolveVW]

in the Mk4 the EGR is bolted onto the manifold, making removing it much easier. There is also a way to minimize its usage through vag-com, but I don't know if the same thing can be done for a mk3

[VWTUNING]

cant I just cap the intake and exhaust manifold where the EGR bolts up? Also was thinking of cutting off the part of the intake manifold that has the EGR valve on it, and getting a longer coupler to make up for it. (since I have to replace that coupler anyway). I would grind a lip into the manifold so it would hold better too. I plan on getting a chip eventually to disable EGR as well.

Thoughts?


Also I broke the PCV disk on top of the valve cover, can I use one from a gasser? or are they different? And if so where is the best place to get a rpelacement?

Also2 - the fitting on the turbo where the oil feed line attaches, does any one have one of those? It looks like this one was changed so they could patch the line with a rubber line (which had a slit in it and appears to be spraying oil onto the firewall and leaking down the turbo. Ryan do you have this fitting off your blown turbo by chance?

[evolveVW]

I have some 1.8t K03 lines kicking around, but Ill be in OR til next Wednesday so Stu would have to dig them out if they would work. A lot of people replace that PCV disc with a catch can. The disc is prone to clogging with carbon build up and it was probably a good thing you broke it.

[VWTUNING]

some pics from last night...


looking into the intake/egr, look at that buildup!!
http://uploader.ws/upload/200806/DSC00011_Medium.jpg

EGR line I had to cut
http://uploader.ws/upload/200806/DSC00013_Medium.jpg

EGR cooler removed
http://uploader.ws/upload/200806/DSC00015_Medium.jpg

Source of oil leak
http://uploader.ws/upload/200806/DSC00016_Medium.jpg

oil leak (you can see how it sprayed the firewall)
http://uploader.ws/upload/200806/DSC00022_Medium.jpg

Broken PCV
http://uploader.ws/upload/200806/DSC00017_Medium.jpg

soaking the intake
http://uploader.ws/upload/200806/DSC00018_Medium.jpg

Fitting that needs to be replaced
http://uploader.ws/upload/200806/DSC00019_Medium.jpg
http://uploader.ws/upload/200806/DSC00021_Medium.jpg

[Jackalope]

That's ahh dirty, Peter :laugh:

Looks like you're going to town on this project. Must feel nice to find the problems others didn't want to find.

[VWTUNING]

Thanks man, Im stoked not only to learn about how this works but to find easy fix issues. Finding problems is like free upgrades when you fix them :icon_cool:



Bump - hoping some one has a fitting off an old turbo and can let me know! TIA :beer:

[VWTUNING]

Looks like the turbo rob gave me has the piece I need - thanks dude!


Got some metal to fab some block off plates and looks like I have some bolts that will fit in my 'extras' bin. Might be able to get it back together tonight!


<---- stoked!

[lotar_6]

sweeeeeeet.

You should put a deep fryer in the back... cook up some french fries to make everybody think you are running wvo!


or just do the wvo sometime.

[VWTUNING]

:laugh:



Got it all back together last night, just in time for some crazy storms and the power going out at the dub spot. Electric garage door + no power and cars inside = stuck! LOL. Ended up getting home at almost 4:30AM! Should be an interesting day :icon_woot:

Car seems to run a lot smoother, but still is making soem noises that might be bad, or might just be diesel noises, like a shutter of sorts. Not sure as I really didnt have time to tinker with it much last night, and I'm a n00b. Oil leak appears to be fixed and might have another smaller one, or might just be old oil dripping off. im looking forward to driving it tonight and seeing how she does on the road (under load) and maybe getting it on the lift to clean up the left over mess and investigate further. The fast/steady drip is now gone so thats good news. Ryan if you have that chipped ECU I would love to try it :icon_cool:

Next priority is motor mounts! Im picking up some hockey pucks on lunch today. Then I'd like to get to exhaust and also mount the boost guage.


p.s. thansk jeff for the help cutting those block off plates, they worked awesome! I'll have some pics up of progress last night soon.

[BUNNYLOVE]

It'll interesting to see how the hockey pucks do with vibration. I ran stiff rubber mounts in a truck for bit and it vibrated BAD. Maybe I can bring it out to you next week. Been too busy to do anything lately.

[VWTUNING]

I bet the hockey pucks are gonna be BADDDD. :icon_eek: But they are cheap and the ones in there now are shot, so I'll give it a try. For $8 why not! :P

If you have a chance to come out sometime that would be great, I would love you to take a look over things and give me some feedback.

[Jackalope]

... I would love you...
he says to bunnylove....:laugh: tgif Pete

[VWTUNING]

There is no 'would' :eek: :laugh:


Ryans helped me more times then I can count, he is the man :icon_tup:

[VWTUNING]

Picked up some used hockey pucks on lunch... $6.79 for 8 :icon_cool:

[VWTUNING]

Any one have an ETKA diagram of the return line setup? Its leaking where it goes into the pan. Im guessing its a bad copper washer.


TIA!

[VWTUNING]

So im getting some seapage through the copper washers on the drain line. It was coming out pretty good so I got new copper washers and the leak improved immensely but its still seaping. The copper washers I got were a tad big and I think thats my problem, any one know where I can get the right size? I need like an M18. I might try vavloline on my lunch break, Kyle seems to think the subies run that size.

The other issue im having is the PCV disk on top of the valve cover - I broke it when i was working on the car and Im not 100% sure what to do about it. I would like to replace it but im not sure where to get the disk. Vinny mentioned running a catch can which is fine with me but shouldn't I still run the disk? I tried to pull the one off my 8 valve but that bitch is stuck!

[BUNNYLOVE]

The disc is an oil separator but a kinda crappy one. You can just run a tube right to a catch can. I blocked off the block vent on mine. I have the pcv disc but it goes to a catch can. The other port is plugged.

I have a spare disc you can use unitl you can find one but I would need it back.

[VWTUNING]

Im gonna see if I can get away with out it, and just run stuff into a home made catch can for now, untill I get a proper one or replacement disk. I'll be working on that tonight.


Got the mounts done last night, holy crap that rear mount is weird!!! Never seen one like that in a MK3 before, it was one solid hydro mount with no lower part. Luckily Jay has a spare for me, so I borrowed Brents (shh dont tell him) and was able to get the car back together. I used hockey pucks on the bottom and some hard rubber (D75 i think) that Jay had. I now drive a giant vibrator :laugh: Any ladies want some rides wink wink nudge nudge :P Car feels solid though, and engine doesnt do a dance when you start it or shut it off. Shifting feels firmer too.

Had some extra time last night so I degreased the hell out of the engine bay and the bottom too (had it up on the lift). I'm stoked with the progress, thinking of putting it on the road this week.

[USOPHUNKE]

lower it!

sounds good pete

[VWTUNING]

Car is on the road! Got it out on the highway and I'm noticing that boost is creeping up when I hold WOT. The N75 valve may in fact be bad or im wondering if the vacumn line that goes to the ECU is too long, ive heard of that causing issues on G60's. It hit limp mode a few times when I stayed on it a long time and saw boost creep up past 20. But normal driving is fine and other than that the car has been very consistent :) Its such a different experience to drive a diesel, its slow but the torue is awesome. Shifter has got some play in it so im gonna investigate tonight.

Any one know where to get diesel purge local?

[BUNNYLOVE]

I thought my N75 was bad but it wasn't. You can run a diagnostic with the vag com that will turn it off and on. That and a little compressed air will tell if its bad or not. The vac hose to the ecu shouldn't make a difference, BUT there is a little vaccum hose inside the ecu that causes issues like this.

I would just check all the vac. lines and make sure the wastegate actually moves when you apply pressure to it.

[evolveVW]

I couldn't find any where that sold Diesel Purge locally.. GAP should carry it.

[vince]

my 1999 tdi golf goes into limp mode and i replaced every sensor and even replace the top intercooler pipe (i jb welded mine) i beleve it is a over lay from the boost pressure sensor to the ecu i guess it is a common problem when you get limp mode issues my car throughs a spordiac intake manfold pressure fault

[VWTUNING]

yeah that was the error i would get when i went into limp mode. it hasnt done it in 2 days though and ive been laying into it more and more. seems like what ever my issue was is slowly working it self out.

fixed the pcv disk, jay had a great idea and i ran with it and it worked well. we heated a small metal tube and melted it into the disk where it broke, then used plastic weld to seal/reinorce it. the hard line that goe to the crank is splitting so I took some hose and made a band-aid. Kinda ghetto but will work or now till I can get a catch can. No more oil spitting into the engine bay.

I was ecstatic to find a keyless module installed, so I programmed a spare banjo I had and I now have keyless entry. :icon_cool:

Also installed a high beam jumper (so low beams stay on when you hit the highs), and eliminated day time running lights. Free mods rock!!! :icon_woohoo:

[Jackalope]

Free mods rock!!! :icon_woohoo:


:mad:...I paid for my tricks.

[FusLit]

:mad:...I paid for my tricks.

Your doing it wrong, the tricks should be paying you...

I'm just saying

-Todd

[VWTUNING]

Diesel purge is available at Advance! Picked up a bottle on lunch, might do it tonight.


Gotta do some research on recomended oil and filter. Recomendations? 15w-40?

[iceVee]

Diesel purge is available at Advance! Picked up a bottle on lunch, might do it tonight.


Gotta do some research on recomended oil and filter. Recomendations? 15w-40?

I use Rotella 15-40 in my wimpy little NA 1.6, but you cool turbo people might want something synthetic and groovy...

[BUNNYLOVE]

I use rotella T 5-40 synthetic (blue jug). Walmart is the only cheap source around for it. Its like $17 for a four quart jug. I use this oil in everything now.
The oil filter is just like an ABA filter but bigger.

[evolveVW]

5w-40 synthetic is recommended... A lot of guys use the Rotella synthetic, I have been using good ol Castrol Syntec

[VWTUNING]

Sweet - I'lll hit up Walmart after work for some. Whats the capacity? Im guessing I'll need 2 jugs?


I heard its good to swap the oil after doing the diesel purge, so thats why im doing this.


Thanks for all the input!

[BUNNYLOVE]

Its 5 quarts IIRC. You will need two jugs.

Are you going to run the diesel purge in a closed system? Don't dump it in the tank its a waste.

[VWTUNING]

yeah im gonna run it straight out the can with the return into the can, I guess you run it like that till there is only about an inch left in the can. then shut off and hook the lines back up to the stock fuel filter. I read some DIY's on tdiclub :icon_tup:

I need to find some clear fuel line and maybe find one of those small inline filters to run on the return.


Have you ever done it before?

[USOPHUNKE]

clear fuel type line at most haedware stores for sinks its the same size and sense its oly for a bit should be fine

[VWTUNING]

Here is the DIY im refering to:

http://forums.tdiclub.com/showthread.php?p=823760

[BUNNYLOVE]

You should be able to find universal filter at the parts store that will work. I did it on my beetle but I just stuck the feed in the can and let the return go to the tank. I didn't know any better.

edit... its all on that thread LOL Anal TDIs guys rock!

[VWTUNING]

Diesel purge went well, although there really wasnt much smoke and I didnt notice much of a difference in power or sound. But im sure it didnt hurt. Also did an oil change with Rototel synthetic, walmart had it for $17 / gallon :icon_tup:

Tried putting in a manual controller to bypass the stock valve (N75?) and im getting a little snappier boost but otherwise no difference really. Tried playing with some different settings and at 20 its still going into limp mode, but creep seems to be gone. Weird thing is it still throws it into limp mode, which I thought was impossible when you override the boost control valve. Im guessing its doing it via drive by wire (feels like it limits throttle to about 30%).


Also decided to pick up some new coils for the black car, so I pulled the used coils off that and installed htem on the tdi :icon_cool: Tried to spin the fronts down but the colars are seized so im gonna have to pull them to free them/clean em up. For now she is sitting pretty good though, so I'm not too worried about it :) Im just happy not to be part of the mile high club any more :icon_biggrin:

http://uploader.ws/upload/200806/DSC00016_Medium_1.jpg

[BUNNYLOVE]

Its all about what the ecu sees for pressure, the N75 doesn't really matter. Stock boost is like 15psi so anything higher than that its going to go into limp mode. If you want to run over 15psi without a chip you have to run a bleed at the ecu so it only sees 15psi or less.

[VWTUNING]

OK, I think im just gonna dial the manual controller down to 15 and make sure I dont get any more limp mode, if I do then something else must be the issue.


Do chips pop up used very often? Or am I stuck buying new? And am I gonna have to buy new again once I get injectors? Or will they reflash for cheap?


This car is slow as balls, I need more power!!!!! :laugh:

[BUNNYLOVE]

Most places do upgrades but I'm not sure how much they charge. Used chips go really quick especially more recent tunes. I might swing out tonight if I do I'll bring the chipped ecu so you can try it out.

[VWTUNING]

Sweet!! The crank trigger is out there if you still need meaurements. Jay was trying to take it off and snapped a torx lol

[VWTUNING]

Some pics from lunch...

http://uploader.ws/upload/200806/DSC00018_Medium_2.jpg

http://uploader.ws/upload/200806/DSC00016_Medium2.jpg

http://uploader.ws/upload/200806/DSC00017_Medium_1.jpg

http://uploader.ws/upload/200806/DSC00019_Medium_3.jpg

[Master_Shake]

dubspot mobile

[tube bias 25]

are those dubspot decals on the front doors or something else you did :confused:

[VWTUNING]

flat black dubspot logo's, just playing around with some ideas. So far I like it :)

[wolfs99]

Dude where did you take those pics .

[kabinotar]

yeah, dubspot!

[VWTUNING]

TDI UPDATE!

Ryan hooked me up with a Watterauer chip and the difference was night and day! She pulls much better and actually accelerates on the highway in 4th and 5th. I am really happy with the results and cant wait to do nozzles.

Ive been having some boost issues and I think Ive isolated it to the electronic controller. Ive been playing more with the manual controller and started by opening it all the way up and slowly tightened it down. Right now Ive got it spiking to ~17 and holding ~15. This keeps me out of limp mode and has good power. Im still sooting pretty good on WOT so I believe that means I can add more boost, but to keep the ECU from going into limp I think I need some sort of bleed off on that line. This is something I need to bug our local diesel experts about, and will prolly start another thread.

I picked up a 3 guage dash pod from Warren (thanks dude!), im gonna pick up boost, EGT, and oil pressure guages. Im not crazy about the dash pod but from a utilitarian stand point I think it will work well. So no more wiper gauge after I get that setup :laugh:


Also just surpassed 400 miles as the gas light came on. Thats with 0 efforts towards getting good mileage. Ive been 'beating' on it learning the power band and tinkering with the issues ive had. Considering I was getting barely over 200 with the VR, I'm ecstatic! A few quick calculations showed $1000 savings every 10000 miles, meaning this car will pay for it self over time :icon_cool:

[FusLit]

Lookin good man :)

-T

[BUNNYLOVE]

Cool, you can just add in a another boost controller in line with your ecu signal to make sure it doesn't go over 15 ish and you then can crank it up a bit to clear the smoke. You could probably use a air compressor regulator for that. 18psi is the recommended limit for old turbos, btw. You can also dial out some fuel with your IQ value.

[VWTUNING]

do you mean 18psi static is the limit or 18psi spikes?

Is the MAP sensor on the ECU only for monitoring? as in - just for setting limp mode? or does it affect fueling? meaning if I run a boost controller on that line am i affecting fueling?


Also - is a Tdi MAF any different than a gasser? I would like to make sure its clean so im gonna pick up some MAF cleaner, but before I do I want to make sure I wont harm it.

[wolfs99]

You can use supper Creep to clean the MAF. I have some if you would like to use it stop buy tonight i will lend you the can.

[BUNNYLOVE]

18psi static.

Pete, the map controls the N75 valve to regulate boost. I'm sure it has a hand in the maps to but I don't know exactly what... I just make sure it sees 15psi no more or less. I figure thats the best we could do.

The maf is specific to the A3/B4 tdi..kinda expensive too. The good news is that they rarely fail.

[VWTUNING]

OK, thanks dude, I think I know what I have to do now to run more boost.


I held WOT on 81 for over a minute today with no limp mode, I think im gonna leave it as is for now while I continue to work out bugs and dial the car in/figure **** out. im friggin ecstatic to get some bigger injector nozzles, but prolly wont do that till im ready to get a new chip at the same time. cause i think with this chip I would have to stay small, but I want big! So I am tentatively planning on staying with these nozzles till I can do a complete upgrade. I got a **** ton more research to do as well...



Filled up on lunch squeezed in 13 gallons; @ 412 miles = 31.7 MPG. Not great for a Tdi but considering all the tinkering, problems, idling, and constant WOT when driving i think im doing alright. im heading to CANADA this weekend and am looking forward to seeing how this baby shines on the highway, cruise control at 78mph should rock! :icon_cool:

Picked up some PS Diesel fuel supplement too, cause it was cheap, works out to >$1 per tank. I'm prolly going over bored but I figured it couldnt hurt on this high mileage engine.

[FusLit]

OK, thanks dude, I think I know what I have to do now to run more boost.


I held WOT on 81 for over a minute today with no limp mode, I think im gonna leave it as is for now while I continue to work out bugs and dial the car in/figure **** out. im friggin ecstatic to get some bigger injector nozzles, but prolly wont do that till im ready to get a new chip at the same time. cause i think with this chip I would have to stay small, but I want big! So I am tentatively planning on staying with these nozzles till I can do a complete upgrade. I got a **** ton more research to do as well...



Filled up on lunch squeezed in 13 gallons; @ 412 miles = 31.7 MPG. Not great for a Tdi but considering all the tinkering, problems, idling, and constant WOT when driving i think im doing alright. im heading to CANADA this weekend and am looking forward to seeing how this baby shines on the highway, cruise control at 78mph should rock! :icon_cool:

Picked up some PS Diesel fuel supplement too, cause it was cheap, works out to >$1 per tank. I'm prolly going over bored but I figured it couldnt hurt on this high mileage engine.

Everyone: So why did your vr turbo project never get finished?
Pete: OMGHI2uBBQTDI!!!!111

;)

kidding, i'm just jealous that you snagged this :-D

-Todd

[VWTUNING]

:laugh:

I swear im still working on that, just need a few more parts :icon_cool:

[VWTUNING]

mileage update: 523.5 miles this tank, took 13 gallons again = 40.27mpg :icon_cool:

[TurboDukers69]

WOW, so how much does that cost?

I filled up 13.765 gallons @ $4.359 a gallon = $60 which comes to around
400 miles.

[boostin20v]

Diesel here in the sticks is ~5.09/gallon

[evolveVW]

At the Hess on Hiawatha it is 4.99. 40mpg is much better Pete. Ill have to explain venting to you so you can squeeze another few gallons in. :wink:

I have been averaging about 45mpg with a heavier car and chipped ecu. (Stu- no granny driving jokes...) I think that will go up when I clean the intake and install the low mile Sprint520 nozzles I just stole :smile:

[VWTUNING]

Yeah I've been getting DZL for $4.99 at the hess by my house or the nice and easy near my work on taft/northern.

Vinny 45 is awaesome, im jeaous :) I bet all the highway driving helps. Ive got a chip now too, and im trying to drive less WOT so hopefully mine will improve further :)

Do you use any additives?

[boostin20v]

im trying to drive less WOT

to best Vin's mpg you'll need to cut out most if not all WOT :laugh::wink:

[kabinotar]

to best Vin's mpg you'll need to cut out most if not all WOT :laugh::wink:

That won't happen with Pete. :laugh:

[VWTUNING]

hahah its true, i cant help it. :rofl:

[VWTUNING]

Yesterday I finally had a chance to mount the orlandos that came with the car. They were pretty rough so I spray painted them before getting tires put on. I was looking for a dark gold or bronze which I thought would compliment the dark green. After 3 trips to various places and not finding any gold or bronze (all they had were metalics) I settled on Satin Walnut Brown...


http://uploader.ws/upload/200806/IMG00015_Medium.jpg
(sorry for the lame cell pic)



I'm digging it :)

BIG thanks to James down at the shop for getting the old tires off for me, and yesterday teaching me how to use the mounting and balancing machines at firestone. it was friggin awesome! I mounted and balanced the full set myself!! :icon_Cool: (and i didnt loose any fingers! haha)

[lotar_6]

you should change up the color every week... see how many colors you can change it till winter.

I'm gonna have to see them in person, but they seem pretty :cool:

I'd luv to learn how to do it... I did learn a lot when I watched them mount mine, but to do it is cool, man!

[FusLit]

Lookin good man :-)

Mounting / Balancing is the one thing that I've watched done multiple times but never tried. It doesn't appear terribly hard (from what I've seen) with the right equipment.

-todd

[iceVee]

$4.89 diesel in Mclean and Alpine Junction... a bit too far south to drive from the 'Cuse, but I was going through on my way to Corning, so I had to stop and fill 'er up.

Tire mounting and balancing is pretty straight forward, but there are a couple tricks you need to know, depending on the type of machine you're using. Gets interesting if you're doing anything tricky like a lot of stretch, or cantilever slicks, or rally tires with super stiff sidewalls. Back in the mid-70s :eek: when I learned how to do this at the Mobil station I worked in, you still had to deal with tube tires pretty often, which were a Big Pain.

I just got my hands on an old Coates spin balancer which needs a little electronic repair. Hopefully I can get the thing fixed. It'll be a big improvement over the old bubble balancer.

[Master_Shake]

Looks good pete. I've mounted and balanced a few tires in my day.

[Jackalope]

Looks good pete. I've mounted and balanced a few tires in my day.

x2^2 did you use the femine product on a stick to lube up the bead?

[VWTUNING]

Soapy water lube FTW!

When the beads popped/seated was a little nerve racking, especially seeing the guy who taught me leaning back out of the way just in case haha.

I got another set to do in the next week, im hoping he'll let me come in and do them as well :)

[Jackalope]

Soapy water lube FTW!

When the beads popped/seated was a little nerve racking, especially seeing the guy who taught me leaning back out of the way just in case haha.

I got another set to do in the next week, im hoping he'll let me come in and do them as well :)

He's leaning back cause he didn't want to get spooge on his face...I can only imagine where it landed after puttin your rubber on the rim...kind of like "Something about Mary" with it being a gel for someone's hair...

[off topic] Our best fun in the shop back in the day was taking an air needle and attaching it to the air compressed grease gun...we cleared the parking lot and got people from the next door bank to look at the two idjuts holding the hose through their lubed windows...not our brightest moves, but we chuckled while we degreased and washed our mess.

[vince]

mounting and balancing is easy i do it all day at work at vw haha the tdi look really good i like it lowered with the gold wheels you guys are paying to much for fuel though i am paying 41cents a gallon for my diesel!!!!!!!!!!! home made i was wondering if any body had a ecu i could try in my car my 99 tdi cuts out in fourth gear and it is tuned with nozzles and i did all the tests to check it and it says my ecu is bad , i wanted to try another ecu ill throw somebody some beer/ money to give me a hand i have a warrenty on the tune but i have to ship it to orgeon to get it tested any help would be greatly apprecated. i also have all the factory test procedures if you wanted them to check your car they helped alot with my car cutting out