Bolts for turbo and manifolds, was Turbo cooling fan?

Post by **HarryMann** » 19 Jul 2007, 21:11

Mine seems to be 'cos the cast lugs of centre housing bearing assembly have rusted away.. although the rest of the thing wasn't too bad, they're much weaker in that region than the equivalent Garrett T2 and the bolts are smaller - and everything the Garrett uses 6 bolts for, the KKK uses 4...

Post by **andysimpson** » 19 Jul 2007, 21:18

HarryMann wrote: Garrett uses 6 bolts for, the KKK uses 4...

Simple solution for that, fit a k24 it has 6 bolts.

Post by **HarryMann** » 19 Jul 2007, 21:40

K24 higher up, would be a nice solution... if I don't have to invest in an investment casting mould for a new manifold design, as well as pay a foundry to cast a one-off with it

Post by **andysimpson** » 19 Jul 2007, 21:54

HarryMann wrote:K24 higher up, would be a nice solution... if I don't have to invest in an investment casting mould for a new manifold design, as well as pay a foundry to cast a one-off with it

My plan is to use a golf manifold and modify something to make it fit a k24 and then make a new engine mount bracket. This is low on my list of things to modify as its very reliable on mine and has no oil related issues.

Post by **Simon Baxter** » 19 Jul 2007, 21:59

if you need any manifolds...

Post by **Simon Baxter** » 19 Jul 2007, 21:59

Infact, a Golf manifold and a 1Y or 1X inlet manifold..

Post by **Macflai** » 20 Jul 2007, 09:26

It would be nice if you are going to develope these projects to see pictures of it...

What happens if you install a "spacer" between the block and the sump.

The only thing is the oil pump is higher but you can add almost 1 litre more of oil... and it is like the turbo would be in higher situation...

Land Rover Defender engine has that spacer, is more or less 2cms high...

I only ask if tha idea could work.

Post by **Macflai** » 21 Jul 2007, 11:02

You know what I mean? Is not a good idea?

Maybe there are higher/deeper (more capacity) sump from VW.. but I don't know it...

Post by **HarryMann** » 21 Jul 2007, 11:53

If you add another 1" of oil, the turbo will be in relatively the same situation w.r.t. draining its bearing well...

If you add a 1" spacer and maybe 1/2" of oil, you''ll maybe get two slight benefits, more oil and a slightly better 'drop' into the sump oil..

But to make such a project economical, the spacer would best be combined with a stiffening girdle around the crankcase skirt with cross-webs for a couple of the main bearings (No. 2 being the critical one it seems, on 1.9TDs)

Provided the bottom of the sump still clears the sump guard plate, and an equivalent spacer is made up for the oil pickup, this might be a 'must have' modification... but wouldn't be cheap (CNC machined from a 1" thick steel plate, with maybe 70% of the metal cut or machined away...)

It might not even be possible; I believe Andy Simpson has looked at having such a girdle made and found there were interference problems.

Post by **Russel** » 21 Jul 2007, 14:09

If u are going through all this trouble u may as well fit the engine upright and solve everithing in one proses.
This is what i am upto to solve all the above problems.This also means u whont have the engine horizontal when offroading.

Post by **HarryMann** » 21 Jul 2007, 16:05

Will help, but wouldn't strengthen No. 2 main bearing cap...

People like kits of parts... is there a 'kit' for an upright mounting?

Raising just the turbo a couple of inches would almost be the ideal solution, thenh the compressor inlet might not also be right in front of the engine mounting

I think we'e just bandying around a few 'in a ideal world' scenarios here

Post by **andysimpson** » 21 Jul 2007, 19:30

There is no room on syncro for lowering sump due to skid plate. The shape of the sump also makes it impossible to fit a girdle.

Russel has the best idea, get the engine running at the angle it was designed for, only downside is getting quality adaptor plate.

Post by **HarryMann** » 21 Jul 2007, 21:46

only downside is getting quality adaptor plate.

or a new cast bellhousing a la RJES Subaru?

Post by **Macflai** » 21 Jul 2007, 22:40

I am going to install the turbo normally, and then pray for a long life...

Long life to the KKKING!!

Post by **HarryMann** » 22 Jul 2007, 00:00

Synthetic or semi-synth turbo diesel oil will help it withstand de rigeours de usage IMHO

Good luck, they can't be thaat bad, after all, VW engineered the installation and fitted them from new