1989 MK2 Golf TDI - Dirty Diesel

[adamss24]

Also on some swaps there is no physical way to fit the turbo as per its native installation, converting to vacuum it’s making things a lot less complex and gives you that necessary room to get your turbo installed as required.
I have soo much room round my pd engine in my mk2 that I can work on it with pretty much everything in place, looking at your car I would hate to drop a 10mm socket in there ! Good effort though !

 

[adamss24]

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• adamss24
• Sep 16, 2023

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• adamss24
• Sep 16, 2023

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• adamss24
• Sep 16, 2023

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• adamss24
• Sep 16, 2023

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• adamss24
• Sep 16, 2023

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• adamss24
• Sep 16, 2023

this is my effort…

 

[CasaEd]

When I worked for the last garage we would cut the flange off the same turbo you are using and weld it directlly to the manifold, it put it closer to the engine and gave more clearance at the back of the engine, and it was still possible to remove without pulling the head off, but fair play to you, it fits without any cutting and welding, my actuator is actually mounted to the hot side of the turbo, and uses a heat shield, also with my turbo I can keep the long lever so I don't have to mess around making a minimum stop or change the lever for the vanes to a short one, because sometimes that is not easy to get it into the optimal postion.

 

[adamss24]

When I worked for the last garage we would cut the flange off the same turbo you are using and weld it directlly to the manifold, it put it closer to the engine and gave more clearance at the back of the engine, and it was still possible to remove without pulling the head off, but fair play to you, it fits without any cutting and welding, my actuator is actually mounted to the hot side of the turbo, and uses a heat shield, also with my turbo I can keep the long lever so I don't have to mess around making a minimum stop or change the lever for the vanes to a short one, because sometimes that is not easy to get it into the optimal postion.

No need to cut flange off the turbo to weld on the manifold, I use darkside adapter plate to fit the gtb2260 housing onto stock AWX manifold mounted upside/down.
The turbo i am using is a hybrid gtb2260vklr with a 69mm Compresor wheel and a amg3.0 tdi style turbine wheel with gtb2260vk hot side housing.
The turbo comes off without taking the head off the block, I rebuilt the engine recently as I was lifting the head off the block and put the forged rods in for good measure.
The car is very fast and I am having issues with traction, I had to limit the torque to 600nm to keep driveshafts in one piece (keep breaking the ball cage on the inner joints).
This mk2 had many turbos along the years, from s300 to gtd40, I don’t race it anymore and kept turbos sensible…still frightens me every time I take it for a spin in the wet !

 

[zipitie.nz]

while Appreciate the discussion, My build thread is now confusing…

 

[adamss24]

while Appreciate the discussion, My build thread is now confusing…

if I am cluttering your thread I could delete my posts…it’s your thread at the end of the day !
I would be grateful for any posts on the forum, the quality posts are getting rather scarce across the boards…

 

[adamss24]

To be honest, most pd engines have a strong following in uk, mainly because cars have become affordable and tuning potential of the pd lump, these have little secrets left unearthed ! Basically one gets on a specialist website, picks a set of injector nozzles (as large as possible so they’re reek of diesel fumes), get a gt1856 hybrid turbo and a questionable map from some spotted kid in a car park and try the popcorn limiter at every corner then they whinge about oil consumption and flog the marketplace with duff turbos when they go pop !
I don’t like much the pd engine, it’s raw and short power band is nothing to write about however it makes good torque from tickover and it’s easy to maintain and build. Throw a few grand at it and you can have supra performance for peanuts with reliability as on the Japanese car !
However the mk2 golf and pd engine makes for an interesting combo, the sheer power of the built engine and light chassis makes it a very potent sleeper while being rare sight on streets !
Keep up the good work mate and enjoy it as much and as long as possible !

 

[burpod]

why do you still have the vac ball there????

 

[zipitie.nz]

I don't, that will be adamss24 wagon.

 

[adamss24]

why do you still have the vac ball there????

Yeah, my turbo is still vacuum controlled...for now...

 

[zipitie.nz]

Flashed my New tune on the TDI over the weekend.

She drives well and makes boost now after the 140hz and signal inversion.

Next steps

get the interior reassembled, and do DTC deletes

 

[zipitie.nz]

Well its been a while, but moved from one island to another so house life has taken priority, however I gave the car a bloody good shakedown the other day, drove it 1170km from a Christchurch to Auckland

it went without a hitch! minor exhaust leak on the down pipe and the turbo oil drain was a leaky ebay special so I have just sourced a much better quality speed flow version

the map that was loaded at the time was rubbish, i have since sourced a smoother less smoky replacement,

i am heeding prior advice and am going to support the turbo with some rose joints and bracketry that said it didn't budge the whole trip

will also be throwing some go fast stickers in to the mix

 

[adamss24]

This car is like a fine wine, it gets better with age ! Credit to you Sir !

 

[adamss24]

I don’t remember from reading your posts, did you have to use any oil restrictor for the feed pipe or the flange is already reduced in size to required oil flow for ball bearing chra ?

 

[zipitie.nz]

I have never bothered with a oil restrictor, the feed line is tiny maybe 3-4mm the drain is 19mm

so that would be restriction enough in itself

 

[zipitie.nz]

Finally finished the Turbo Support

 

[zipitie.nz]

Well, I can confirm the Stickers have added an additional 10hp

 

[zipitie.nz]

Well She is now back together again,

Will do a shakedown drive tonight and see where the next oil leak springs from.

Also took the time to modify my Gas pedal. Since the car was made it has never quite sat in the right place.
Sat slightly to far away from the Brake Pedal and actually sat higher,

I don't currently have a workbench or Vice So made do with Cutting and welding in a piece of Steel Rod to move it to where it needed to be.

Feel free to laugh at my shonky ass welding.

The Engine bay is all plumbed back up, I quite like how it has shaped up.