Building a Syncro 2li 16v Turbo

Over the last month I have been amassing the parts necessary to build my next project and my first turbo.

I am missing a couple of parts as they are hard to get, or are from overseas and Ive had to send stuff away to be modified. Stay tuned I start the cage next week, Cheers to the guys who have helped so far. Pictures to follow.

The beginning

The Shopping List:

Management
Full Megasquirt kit V3 (Aquired)
EDIS System (Aquired)
Injectors, Saab, 2.3 Turbo (Aquired) G60s & Saab 2Li turbo (Aquired)
Fuel Rail and FPR 1.8 Turbo, (Aquired)
BBM / Ross Rail (Waiting)

Engine
ABK 2Li Block (Aquired)
Standard Pistons and Rods (Aquired)
ARP rod bolts (Waiting)
2 x ABF Head Gaskets (Aquired)
New oil Pump (Aquired)
Bottom end Gasket Set (Aquired)
Full Baring Set (Aquired)
Modified Exhaust Cam (Waiting)
Ported Head ( Home Made)
Race Veneer (Aquired)
Turbo Technics Turbo System (Aquired)
G60 Throttle Body
K03 Turbo Sytem (Spare) and Adapter flanges (cheers Dave)
21/2 SS Exhaust System

Internal
Corbeau Forza x 2 (Aquired)
Seat Subframes (Aquired)
Race Harnesses x 2 (Aquired)
Custom Rollcage (Metal Aquired)
Passat GT Pedal Box (Aquired)
Extinguisher (Aquired)

Drive Train
Rally rear Diff (Waiting)
O2C 4X4 Cable Change Gearbox (Aquired)
New Clutch. ( Aquired)

Cooling
Cossy Intercooler (Aquired)
Mocol 13 Row Oil cooler Kit (Aquired)
Cossy Intercooler (Aquired)
Passat GT Radiator (Aquired)

Chassis
Poly Bushes (Still to Order)
Suspension (Still to Order
280 Brake Kit (To be Refurbed)
Rear Drum to Disc Convertion.

Plan of Attack

1. Roll Cage

2. Engine Rebuild

3. Install pedal box and Cable Change

4. Install Engine and gearbox

5. Fit rear diff and disk convertion.

6. Install Megasquirt

7. Install Cooling System and Induction Systems

8. Set up engine.

9. Install Interior

 

HAY MATE SOUND NICE HOPE IT ALL GOES WELL.


PLEASE KEEP EVERY ONE UPDATED ON THE PROGRES MATE





WOODY

 

Steph - you always have to go one better don't you!

Sounds great, keep us updated!

 

depending on the power output you might wanna change to a Haldex system not syncro.....

 

Don`t think you need the G60 throttle bodt, the normal 16v jobby and a BOV may be a better choice?

 

Keith, I'd guess he wants it because it has a throttle position sensor?

 

Atomatic Passat maybe a better chice with the tps? mine`s just got idle and wot switches on it ..

 

An Audi 7A engine t/b has a TPS and will bolt to the 16v inlet manifold.

 

I knew Mr. 222272727272727777 would be involved somewhere along the line when I started reading the list.......

 

Do you know of a way of getting the haldex working properly without ABS and bosch managment?

 

Yep, planning on using the G60 TB for the TPS, I did look at some audi ones but the TT inlet manifold adapter didnt look as if it could bolt on.

Not sure what sort of power I will get from the TT garret turbo, but I would hope the 02C gearbox will take it,

I have no idea what a haldex system is

If you think ive missed anything give me a shout and a nudge in the right direction.

 

Haldex is from an Audi TT/A3 quattro etc. The best way to fit the system is with a 5 speed box. It is VERY strong unlike the syncro system from the Rallye's etc. MBE have a function on the ECU to plumb in a diff or traction control so you can hook up the haldex system to that. When the front looses grip the back cuts in to help out much like it does on the TT etc.

 

you need the matching rear diff from the tt or your wheels will rotate at different speeds

 

I've got the Skoda O2C 5 speed transferbox and a haldex.I thought the Haldex input signals where via the can-bus, Can MBE produce these signals?

 

Ive got a slight issue, I am trying to find some info on the compressor on the turbo, there are 4 pipes I need to know where they go to,

I recon

number 1 goes to the sump,

Number 2 ?

Number 3 either the head or the oil filter housing

Number 4 ?

I will work it out eventually






What do you think ?

 

No. 2 any oil pressure feed
No. 3 and 4 coolant flow and return

 

Surely no 3 is the oil feed?

edit - on the bottom pic anyways
Edited by: GVK

 

no 2 doesnt look as if it has a big enough to flow the water volume

 

I with Gary 3 being the oil feed

 

<DIV>No 1: Sump</DIV>
<DIV>No 2: Coolant pipe </DIV>
<DIV>No 3: Oil filter housing </DIV>
<DIV>No 4: Coolant pipe </DIV>
<DIV></DIV>
<DIV>Sorted!</DIV>