fuslit
Veteran Member
Hello everyone,
Thought I'd post up a project I'm putting together: (I posted this over at vwdiesel.net as well, sorry for a copy paste, but thought I'd look for input here as well.)
Anyway, my daily driver is a 98 tdi jetta with some pretty bad rust issues in the gas tank and trunk area but drive train is decent. It's got 193k plus or minus a bit, I did the timing belt, tensioner rollers at 180k water pump not long after... (should have done it at the same time... oops) put new glow plugs in, new glow plug harness and a few other maintenance items I'm forgetting off the top of my head.
The current mods:
- stage 2 chip from malone tuning http://malonetuning.com/?page_id=62
- downpipe back straight pipe (my exhaust rusted out, this was the cheap replacement for the moment)
- larger injectors (Sprint 764)
- boost gauge
current problem:
At the moment I have a random (not repeatable) intermittent boost issue I haven't been able to pinpoint. I believe is associated with my turbo's waste gate sticking (when I bought it it was frozen up, I managed to free things up with pb-blaster and some vise grips and moving things around, it's not exactly an easy spot to reach.) but my n75 valve could also be part of the problem. While I'm doing the swap I will pinpoint where things are freaking out.
After looking at the body work that I'd need to do and by chance my buddy was parting out his turbo vr6 jetta which lined up a pretty much rust free glx. Based on the cost of bodywork, and upgrades that the glx would have I worked out a price with him and I'm buying his shell for the swap.
Things the glx shell has on it: (and should come with, going to be picking this up friday)
- clean title / fresh paint
- no motor/trans/radiator
- no engine wiring/ECU/cluster
- no emissions stuff
- will have shifter box and hydraulic clutch stuff.
- stock 5x100 15" wheels, stock suspension. will have axles.
- will have 11.3" brakes / rear disk with newer MK4 calipers. stainless lines. ebrake holds.
- control arm: polly bushings in front. R32 rear
- no seats; will have black door panels. black dash. black carpet.
- neuspeed upper tie bar.
- neuspeed front and rear lower sways
- 2.5" TT stainless borla exhaust with TT test pipe
- stock headlights
Things the shell needs fixed:
- passenger fender kinked. front/rear bumper needs paint.
- bad steering rack (i dont think yours will work). pressure line also needs replacing (your line should be fine)
- no seats, door cards will be swapped over with a k2 jetta door card. (I'll be swapping in my seats which are from a 95 glx)
Things I'll swap over from my current tdi:
- Suspension from my current tdi (noname cupkit)
- motor & transmission
- engine bay wiring harness
- gas tank
Things I have ordered or am building or have on hand for this swap for upgrade/replacement:
- Stuff to make a stainless downpipe
- ebay cxracing fmic from ebay
- new motor mounts (g60 solid transmission mount, oem front and rear engine mounts)
- new strut bushings
- aircraft spruce egt probe (plan on connecting a vdo gauge I have hopefully it's the correct type)
- manual boost controllers (I'm picking up two of these to use until I get things dialed in)
Fabrication: (works in progress)
- short shifter (a friend of mine makes these, I'm getting a decent price on it so I'll try it out)
- the downpipe
- custom 3 gauge holder thinking about a green sand casting of one I have now but it needs some work.
- building a custom intake from a volvo d24 (egr delete) ported and polished
a couple images of that so far (I've beadblasted it and my buddy will tig-weld it for me)
- k24 turbo from an audi 5000 diesel (will custom exhaust adaptor & or manifold adaptation to make things work correctly)
The info I've pulled from it shows that it's a k24 from a 2.0L audi turbo diesel seems to be in decent shape. I'm thinking about pushing in the range of 20-25psi (I would like some input on this particular turbo, has anyone here run them on a tdi? also sorry for stupid questions, I haven't found any maps on it and am still learning about turbos.)
http://www.turbo-product.com/KKK/K24.ASP
model # I found 069145703 shows the following
- paint bumpers and one small ding
- Once things are up, running (and most importantly stable) I will look into an upgraded 3 bar MAP then get another custom tune from malone for some more power.
- Find out what it would take to get the MFA working (using a vr6 cluster, mod the tachometer I've read a bit about it but it's on the back burner at the moment)
The goal of this project is to have a decent reliable daily driver that has enough power to pass when I need to, and have a fairly good mpg. my commute is about an hour one way so most important is it needs to be reliable. That said, the glx will have tons of upgrades that my current one lacks, an interior for instance because I have a huge rust hole in the trunk area that is letting water in...
Anyway, thanks for reading (and stay tuned) I am gonna try and wrap this up by September! (a lofty goal for me)
-Todd
Thought I'd post up a project I'm putting together: (I posted this over at vwdiesel.net as well, sorry for a copy paste, but thought I'd look for input here as well.)
Anyway, my daily driver is a 98 tdi jetta with some pretty bad rust issues in the gas tank and trunk area but drive train is decent. It's got 193k plus or minus a bit, I did the timing belt, tensioner rollers at 180k water pump not long after... (should have done it at the same time... oops) put new glow plugs in, new glow plug harness and a few other maintenance items I'm forgetting off the top of my head.
The current mods:
- stage 2 chip from malone tuning http://malonetuning.com/?page_id=62
- downpipe back straight pipe (my exhaust rusted out, this was the cheap replacement for the moment)
- larger injectors (Sprint 764)
- boost gauge
current problem:
At the moment I have a random (not repeatable) intermittent boost issue I haven't been able to pinpoint. I believe is associated with my turbo's waste gate sticking (when I bought it it was frozen up, I managed to free things up with pb-blaster and some vise grips and moving things around, it's not exactly an easy spot to reach.) but my n75 valve could also be part of the problem. While I'm doing the swap I will pinpoint where things are freaking out.
After looking at the body work that I'd need to do and by chance my buddy was parting out his turbo vr6 jetta which lined up a pretty much rust free glx. Based on the cost of bodywork, and upgrades that the glx would have I worked out a price with him and I'm buying his shell for the swap.
Things the glx shell has on it: (and should come with, going to be picking this up friday)
- clean title / fresh paint
- no motor/trans/radiator
- no engine wiring/ECU/cluster
- no emissions stuff
- will have shifter box and hydraulic clutch stuff.
- stock 5x100 15" wheels, stock suspension. will have axles.
- will have 11.3" brakes / rear disk with newer MK4 calipers. stainless lines. ebrake holds.
- control arm: polly bushings in front. R32 rear
- no seats; will have black door panels. black dash. black carpet.
- neuspeed upper tie bar.
- neuspeed front and rear lower sways
- 2.5" TT stainless borla exhaust with TT test pipe
- stock headlights
Things the shell needs fixed:
- passenger fender kinked. front/rear bumper needs paint.
- bad steering rack (i dont think yours will work). pressure line also needs replacing (your line should be fine)
- no seats, door cards will be swapped over with a k2 jetta door card. (I'll be swapping in my seats which are from a 95 glx)
Things I'll swap over from my current tdi:
- Suspension from my current tdi (noname cupkit)
- motor & transmission
- engine bay wiring harness
- gas tank
Things I have ordered or am building or have on hand for this swap for upgrade/replacement:
- Stuff to make a stainless downpipe
- ebay cxracing fmic from ebay
- new motor mounts (g60 solid transmission mount, oem front and rear engine mounts)
- new strut bushings
- aircraft spruce egt probe (plan on connecting a vdo gauge I have hopefully it's the correct type)
- manual boost controllers (I'm picking up two of these to use until I get things dialed in)
Fabrication: (works in progress)
- short shifter (a friend of mine makes these, I'm getting a decent price on it so I'll try it out)
- the downpipe
- custom 3 gauge holder thinking about a green sand casting of one I have now but it needs some work.
- building a custom intake from a volvo d24 (egr delete) ported and polished
a couple images of that so far (I've beadblasted it and my buddy will tig-weld it for me)
- k24 turbo from an audi 5000 diesel (will custom exhaust adaptor & or manifold adaptation to make things work correctly)
The info I've pulled from it shows that it's a k24 from a 2.0L audi turbo diesel seems to be in decent shape. I'm thinking about pushing in the range of 20-25psi (I would like some input on this particular turbo, has anyone here run them on a tdi? also sorry for stupid questions, I haven't found any maps on it and am still learning about turbos.)
http://www.turbo-product.com/KKK/K24.ASP
model # I found 069145703 shows the following
Things that will need to happen once swap is complete:Turbocharger - KKK
Mark - Audi
Model - 100 TD
Year - 1981-01
Engine - 720/5 (2.0)
H.p. - 87 D
Family Turbo - K24
Turbo Code - 53249706081
O.E.M Turbo Code - 069145703 3K (maybe this is the max rpm?)
- paint bumpers and one small ding
- Once things are up, running (and most importantly stable) I will look into an upgraded 3 bar MAP then get another custom tune from malone for some more power.
- Find out what it would take to get the MFA working (using a vr6 cluster, mod the tachometer I've read a bit about it but it's on the back burner at the moment)
The goal of this project is to have a decent reliable daily driver that has enough power to pass when I need to, and have a fairly good mpg. my commute is about an hour one way so most important is it needs to be reliable. That said, the glx will have tons of upgrades that my current one lacks, an interior for instance because I have a huge rust hole in the trunk area that is letting water in...
Anyway, thanks for reading (and stay tuned) I am gonna try and wrap this up by September! (a lofty goal for me)
-Todd
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