Turbo Project Update #2

[Alexander van Gerbig]

    Well it's been a few days since I posted any progress, so for those of
you interested here it is.

    Shop took 3 full days to swap low compression pistons to old rods and
install new rings.  This left me without anything to do for two days because
the subframe was down and the engine was hanging by a chain from a support,
not very stable.  So today I became fed up with waiting for the pistons and
I put the subframe back up to support the engine by the mounts (the engine
in a 4 pot is supported by the subframe only).  With proper support and some
stability I was able to put the head back with the turbo and intake
manifold.  The intake plumbing got tackled first and proved to be quite a
pain.  Space was much more limited than I expected, but in the end I luckily
swapped some silicone bits around and found a good way to get everything
properly fed.  I then turned my attention to the vacuum system, which was an
even bigger pain in the end.  Rerouting the brake feed, ISV, and the
crankcase breather proved to be a real PITA.  I had to move the crank case
breather because it severely interfered with the turbodiesel oil filter
bracket I am using to feed the oil cooler.  This also occurred with a main
hard coolant line.  I had to chop it and replace with a flexible hose, not a
big deal.  Getting the injectors across isn't a big deal, but the first
injector actually has to go underneath the throttle body to reach the seat
properly.  The cold start injector uses a super long Golf fuel line which
loops underneath the intake manifold and comes back around.

    Things are coming along well, but it's still far from perfection.
Tomorrow the pistons go in and the head finally gets permanently bolted up.
I have to do some more intake modification to get the bypass valve installed
properly, but it shouldn't be a real pain.  This engine looks entirely
non-stock now, not even a hint of stockness to it.  I didn't particularly
want it that way, but everything is ass backwards with the GTi head on and
all that intake plumbing.  Once it's all done I hope I can clean things up
and bit and make things a little neater.

Cheers!

Alexander van Gerbig -- '88 80

The Audi  80 Pages-----------------
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North Ferrisburg, VT 05473