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Project Bella- 1991 Jetta Coupe 1.6D + A Turbo

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colejerk

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Discussion starter · #1 ·
Well i pulled the trigger. Since i have been in withdraw from selling my last mk2 (almost 4 years ago) i have been looking for another replacement. I have always been fond of jetta coupes and i used to love my old tdi so i was on the hunt for a jetta coupe TD.

Everybody Welcome Bella.



The previous owner did some nice modifications to it. Right now the main issue is that the turbo is showing its age and is leaking a quite a bit of oil.



The turbo is out. this is by far the easiest turbo i have removed. lol 4 bolts and its out.


I started to disassemble it for a rebuild



Lots of oil in this snail. No Bueno. Letting the hot side of the turbo soak in some JB 80 for a couple of days to free it up. Going to be rebuilding the turbo with a Dieselicious rebuild kit.
 
Discussion starter · #3 ·
So I have been thinking lately... I found this turbo on eBay. It looks similar to a k24 but the wastegate looks different. It would be awesome for a external dump. Anybody use these turbos? Good or nah?
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Discussion starter · #4 ·
Some updates :) I removed the heavily cracked dash to be replaced with a not so cracked one.
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. And The replacement
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. Thanks vw90! Awesome service. Great seller! I mainly took the dash out to replace my heater core.
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. Bye bye old pos. Since the dash is out mine as well remove the interior for a deep clean.
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Found some bullets and cigs. Sweet! Quick vaccume
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. And rip out the carpet to power wash and scrub.
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. Way better! Cleaned up my oem floor mats too
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. This interior is going to look brand new. Almost...


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Discussion starter · #7 ·
On a side note...
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This clean evo came into the shop for a trans rebuild. Even as a Evo specialist this is the nicest and cleanest one I've seen that has a stock bottom end. And only 40k miles! One day I'll scoop one up.


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#8 ·
The fuel pump appears to be from an AAZ (?) due to the electric fuel (cold start) mechanism on the front of the pump.
Don't forget (overlook) recovering your heater blend doors with aluminum stove pipe tape or something while you are working on the heater.
 
Discussion starter · #9 ·
Prairie said:
The fuel pump appears to be from an AAZ (?) due to the electric fuel (cold start) mechanism on the front of the pump.
Don't forget (overlook) recovering your heater blend doors with aluminum stove pipe tape or something while you are working on the heater.
Click to expand...
Thank you for the information. But why would I want to recover the blend doors when I'm working on the heater. Prevent a rodent living in there? Lol


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#10 ·
Probably to keep yer a$$ warm. Perform a search on heater repair.

If you are truly interested in a turbo engine which runs well, pull the head, properly rebuild it, and port the intake and exhaust ports and matching manifolds.. It not only does away with most of the turbo lag, but it allows more power, gets the heat into the turbocharger to rotate the vanes, and then removes the heat from the head to avoid heat damage.

For me, porting is primary to the whole shooting match. You can turbo all you want, but, it is like putting a high volume air compressor in front of a soda straw. You lack flow and you build heat....destructive heat. Just my real-world take.
 
Discussion starter · #12 ·
cbaumy34 said:
Solid car!!

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Click to expand...
Thank you cbaumy34. The previous owner really took care of it. It's funny because it looks stock as hell but there is quite a bit of things done to it so far. I'm just taking it to the next level. Let's just say apr head studs are involved hahaha.

I was surprised my self how rust free and solid the chassis was myself when I bought it.


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Discussion starter · #13 ·
Prairie said:
Probably to keep yer a$$ warm. Perform a search on heater repair.

If you are truly interested in a turbo engine which runs well, pull the head, properly rebuild it, and port the intake and exhaust ports and matching manifolds.. It not only does away with most of the turbo lag, but it allows more power, gets the heat into the turbocharger to rotate the vanes, and then removes the heat from the head to avoid heat damage.

For me, porting is primary to the whole shooting match. You can turbo all you want, but, it is like putting a high volume air compressor in front of a soda straw. You lack flow and you build heat....destructive heat. Just my real-world take.
Click to expand...
I agree with you 100% on the head porting. Right now I am just trying to make it drive good the way it is now for a bit. I will probably work the head next winter.


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Discussion starter · #14 ·
Small little update. My mudflats came in. I had a pair up front but it looks like the tears were ripped off at one point. These are actually in pretty good condition
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. The bottom two look like they have never been mounted to a car! If anybody has 2 NOS flaps like the one on the top of the picture I'll trade you for 4 of the ones that I have that are in good condition. Another goodie also came in the mail
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Tessa felt tape to wrap the wiring harnesses under the dash. I tore off all of the old dusty foam wrap and am replacing it with this. I didn't think $5 a roll was bad off of amazon. I really need to put the interior back together this week. I want to start driving her!!!!!


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