Building a Syncro 2li 16v Turbo

Nice one Dean, photos are spot on

 

Went to see a turbo specialist and took my turbo technics system with me,

Well it not great, the turbo is pucka however Its no use for a track car and i could easily blow it up. The guy did say he would take it off my hands and he was very keen on the exhaust manifold.

My K03 system that I aquired for a fall back is also not going to be enough for what I want either, not enough boost, 12psi and it probably wouldnt last long on track either so nothing like a couple of knock downs.

Well its Third time lucky, Ive just purchased the replacement system. This being my first turbo I was advised not to bodge It would cost me more in the long run.

So off to germany I went and bought this little lot

Brand new K04-023 turbo,



exhaust adapter plates



Inlet manifold adaptor plate.


I did attempt to start on the rollcage and then it poured down and the car started filling with water so I had to shove it back in the garage

Went back to my workshop and did a couple of jobs

I deep cleaned the engine block and shoved it on the stand, dryied it off with the heat gun and painted it with enamel.



next I sorted out the intermediate shaft, Matched the shaft up with the correct oil pump pully then I had to remove a notch then make a notch in the KR pully. Job took 20min and it fits tight and perfectly.

 

talk about job on mate!! did you see the green 3 dr turbotechnics syncro on the bay recently? might have been a shortcut for you.





nevermind post some more pics mate as your project progreses

 

Glad to see it coming along!

 

The haldex ecu does get its datavia a CAN-bus from the car ECU. Even if your management does have a can-bus out, I'm not sure if it will be correctly configured to give the information in a readable way.


The haldex ECu also takes in around 11 different data streams and I'm not sure if you miss one on them out whether the haldex will work properly, or go into "limp home" mode.


I've designed a stand alone Haldex ECU and control program, but the final model won't be completed until I've got my project car on the road. That is a long long way away.....

 

The haldex ecu does get its data via a CAN-bus from the car ECU. Even if your management does have a can-bus out, I'm not sure if it will be correctly configured to give the information in a readable way.

The haldex ECu also takes in around 11 different data streams and I'm not sure if you miss one on them out whether the haldex will work properly, or go into "limp home" mode.

That is way beyond my capabilities, however I did see a haldex rear diff on ebay for 360ish and the 6 speed box went for 350 ish,.

I will stick to cable change box and diff that ive got from germany so I dont have to worry about the complicated haldex and is ecu stuff

 

Matt at Designadubs, had the hadlex running in nutter's car for a couple of years

Also motorhead has it in his limo, he is on original ecu tho 20v ecu could run a 16vt too

 

Well the workshop is full of boxes with lots of nice thing , I will unpack at the weekend and take a few snaps.

I sorted out the inlet manifolds and its ready for welding together baring a good clean. Nipping over to Dan's(Neo) on Saturday.

The turbo inlet is made up of 2 manifolds, the bottom section is the bottom part of a 50mm manifold and the top part is from a 42mm manifold, the reason I couldnt just use complete 50mm is that the top half of the manifold wouldn't once cut, mate up close enough for welding because the gap was to large, sort of like a rectangle attaching to a square, anyway having lots of parts spare is handy, so I had to chop the 42mm manifold to size.

 

Well Ive started unpacking, everything is here I think. There is no excuses to get it built other than time so I will book a few days off and get cracking.

The EFI set up and a spare laptop I bought just the car.






MS V3 setup with spark






My brand new K04 with custom manifold and exhaust adaptors and the inlet manifold thats getting welded tomorrow. The ally tubing came via my stores so I can connect the induction system and limit the amount of silicone hoses.





The engine components, these have come back from a very hot golf girl in Wales, she likes to turn metal.

The flywheel is about half the weight it was.







the pistons are well pucka and will bring the compression down to 8:1 without the use of a spacer plate or staking gaskets, Mart your a diamond gezza.
Edited by: stephcasscar

 

Thats the inlet finish, it just needs a good clean out.

I done the cutting and Dan (Neo) done the welding and tarted it up a bit.

The front face was off a couple of mm, so Dan took me to a machine shop and had that skimmed down.











I have notice another issue that needs te sorted but other than that, we have a goer.

 

Looking good Steph! Excellent work!

 

Looks like Dan did a decent job of the welding, i've seen some right pig-ugly jobs done of that before

 

Wasn't too bad to do in the end. Looked like it was gonna be a pig to get the torch between but went ok.
Was going to flush all the welds right back with the die grinder but i think Steph wanted to get back home and get it fitted!

Could either extend or angle that pipe without too much aggro m8. Btw......... you know that steel bracket we took off....... its still on my bench if you need it!

 

i love that inlet manifold fella, great work

 

Dan, Just stick the cable clamp in the bin mate i have a few.


Ive had another look for the conrod cap and it is lost so ive got to dig the 2e engine out and nick one from that.

and I cant fine my cylinder hone anywhere so I need to put one of those on order.

I really need to clean the workshop out again.

 

If your gonna use a new cap, get it to a machine shop and have them lightly skim the matting faces of the cap and rod(only a thou or 2), bolt it back on and re machine the big end to size. If you don';t you could run the risk of spinning a bearing on an oversize bore or even clamp the bearing to the shaft and knacker you running clearence.


Or just use the whole rod

 

indeed. i wouldnt mix the rod caps up.

 

Lucky I mentioned it then or I may have made a balls up.

I pulled the 2e out last night drained the oil whipped the sump of and stole the cap, now I will have take the head off tonight to get the piston out

Best doing it right though.

 

Spent some time today stripping the passat, boy it was cold, burrrrrrrrr.

Took the wide track set up off, The cable change set up and the master and slave cylinders and the pedal box out.

Filled my trolley right up

roll on christmas leave, I am hoping to get the cable set up installed in the syncro. and the rest of the body stripped.

 

I can't wait for all this to come about. I have some plans of my own but I need some prodding in the right direction!!
Keep up the posts mate, need anything done, let me know