1.6TD tune up help please (& importance of TD air filters!)

[HarryMann]

would be good to change the paper filter for a pipercross or something else..?? ...anything to help

NO - it wouldn't, many make that mistake - Salesmen, ££ and sales blurb, don't listen to them... VW aren't idiots! That TD filter is a cyclone (you did empty the centrifugal cyclone chamber, in the end-cover?) and large surface area cartridge combined*

What does improve situation, is the sort of mod that PC52 has done, which is to put an 'unking great dual chamber air-filter from a large plant machinery, in the Dead-man locker of his Doka, and connect up securely tight back to the turbo inlet.. so you get 3 levels of filtering plus very large surface area (which is what it's all about!).

The 1st is for dirt & pollution to even get into the locker...

* the secret is to arrange the inlet into the filter to be from a clean and cold air source, if it's picking any air up from inside the engine bay, you're knackered from the off, seal a tubular/hose to outside air as high up as possible.

** The filters are not 'that' expensive from the right supplier, and should be changed regularly (I'd say almost at oil change intervals) or on condition

[Simon Baxter]

Only syncro have the extra cyclone on the end of the can, 2WD models unless destined for dusty climes have that extra filtration element.

[HarryMann]

Aha! Another Syncro 'difference'... ta!

Choplee, so worth a quick look? It's a black plastic moulding insert with a collector slot, arrowed to be aligned roughly at the top, so the end-cap has to go on the right way... the other (entry) end has a set of angled radial vanes, again a plastic moulding.

they pick up mainly the really big stuff, leaves, dry vegetation but some grit too. Those TDs really suck This must end up in the canister around the element otherwise.

[T-3PO]

** The filters are not 'that' expensive from the right supplier, and should be changed regularly (I'd say almost at oil change intervals) or on condition

What would you say is the lifespan (miles and years?) on air filters as in truth I don't know what is considered to be the oil change intervals I tend to change my oil every year having only done about 4k inbetween. The air filter is checked regularly enough, esp before a long run, and is still fairly clean so not sure of the need to change it though I heard something (not neccessarily relating to VW's) about changing an air filter every 2 years regardless of mileage due to it getting damp from moisture in the air, condensation etc and made worse in cars/vans used less.

[choplee]

Harryman...I'll have a look when i pickup my filter today ..I can't remember seeing any collector ,but just a big hole on the nearside next to the wing which looks like it may have been longer or have a corner on it ,as it's been sawn off ...i could be wrong .

ps ....know where i can get the oil filler dip stick plastic tube ,as mine seems to be cracked and leaking (new or 2ndhand)....

Aha! Another Syncro 'difference'... ta!

Choplee, so worth a quick look? It's a black plastic moulding insert with a collector slot, arrowed to be aligned roughly at the top, so the end-cap has to go on the right way... the other (entry) end has a set of angled radial vanes, again a plastic moulding.

they pick up mainly the really big stuff, leaves, dry vegetation but some grit too. Those TDs really suck This must end up in the canister around the element otherwise.

[HarryMann]

Air/oil filter change interval

Oil - up to you, 3,000 miles ?
Air ~ anything from daily (cleaned mine every night off-road in the Pyrenees, very dry tracks, blocked with dust)
to yearly I'd say, I don't know the quoted service interval, others will, but I wouldn't take much notice of it....
Because really it's on condition, but do have a 'close' look regularly and at least knock it out, stiff bristle brush or use a heavy vacuum to clean the folds whenever you take it out.

Harryman...I'll have a look when i pickup my filter today ..I can't remember seeing any collector,but just a big hole on the nearside next to the wing which looks like it may have been longer or have a corner on it , as it's been sawn off ...i could be wrong .

That sounds like its picking up engine-bay air then

[choplee]

AIRFILTER changed ...
Took out for a spin ,but not that noticable difference really . ..
I'm out camping this weekend ,so i'll see how she is up the top end ..That part not an issue it's the 1st -2nd gears praying not stopping on a hill or go up one ... .. When the turbo cuts in she does go better ,but then the engine is fighting to get out the back ....pull off just die's and needs full throttle to get her to go ..

Helllpppp...lol

Air/oil filter change interval

Oil - up to you, 3,000 miles ?
Air ~ anything from daily (cleaned mine every night off-road in the Pyrenees, very dry tracks, blocked with dust)
to yearly I'd say, I don't know the quoted service interval, others will, but I wouldn't take much notice of it....
Because really it's on condition, but do have a 'close' look regularly and at least knock it out, stiff bristle brush or use a heavy vacuum to clean the folds whenever you take it out.

Harryman...I'll have a look when i pickup my filter today ..I can't remember seeing any collector,but just a big hole on the nearside next to the wing which looks like it may have been longer or have a corner on it , as it's been sawn off ...i could be wrong .

That sounds like its picking up engine-bay air then

[HarryMann]

Took out for a spin ,but not that noticable difference really .

Economy will though..

Can't make too much sense of the rest , but get the approx. idea it doesn't pull away strongly... ?

The turbos on JX's don't really 'cut-in', its not an early petrol turbo 'on the turbo or off it' at all..

It should be boosting by 2000 and by 2200, definitely 2500 say pulling nicely. A 1.9 will be at least 200 rpm less... starting around 1800

It's possible your turbo wastegate is leaking or holding off, but more likely the LDA mechanism is broken, which happens on them.

LDA diaphragm on injection pump is connected to the post turbo inlet manifold sensing boost pressure. As boost develops it adds more fuel. Various things can go wrong, the small bore (carb vacuum like) pipe can be disconnected, blocked or leaky, or the mechanism can break.

Alternately, inlet or exhaust manifold leak, Blow Off Valve loose or leak (BOV).

Some diagnosis can be done by exhaust colour/smoke/amount for various conditions

Alt.bad > the engine is worn/damaged and lost compression or has a cracked head.

Does it get hot and bothered? Lose any water (head can still be cracked, and not lose water)? Keep oil clean for more than 5 minutes etc

That sounds like its picking up engine-bay air then

No answer ?

[Titus A Duxass]

I'm going to start my tune soon.
I managed to pick this lot up for 50 yoyos.

That's a Micrometer, Shim removal pliers, Bucket depressor and 60 various shims.

All I need to buy now is the DTI adaptor from Brickwerks and I'll be set.

[HarryMann]

Cor, 50 yoyos... blinding snatch.

[choplee]

Hi Harry ...Just about to go camping ,so i'll see what she's like on a run ...I'll get back to you on sunday ..shame your not local to me could do with someone with knowledge to help .

Took out for a spin ,but not that noticable difference really .

Economy will though..

Can't make too much sense of the rest , but get the approx. idea it doesn't pull away strongly... ?

[T-3PO]

... but just a big hole on the nearside next to the wing which looks like it may have been longer or have a corner on it ,as it's been sawn off ...i could be wrong .

Hey choplee, didn't want to reply earlier until I'd done some work on my own. It'd be easier if I could link to a pic but as vagcat is no more ...

There should be a flexi pipe out the side of the air filter cannister, into a right angle piece (it could be the extra filtration unit Baxter mentions as it sure doesn't look like any old right angle connector in the vagcat pic ) which connects to the bottom of the snorkel pipe which goes up the inside of the nearside are intake. The flexi pipe is still available from VW but the right angle isn't so some bodgery is required!



The pipe going up is oval but I gave it a squeeze and shoved the new flexi pipe into it with cable tie to secure. I needed to completely remove the air filter cannister and one of the brackets to get easy access to it but this gave me the chance to wash out the cannister and remove the big plastic insert inside it ... it was filthy!!! 25 year build of cack removed with hot soapy water and left in the sun to dry Fitting in reverse but I couldn't get the new pipe back on to the air filter cannister so I had to remove the rear light cluster for more space.


Turbo Diesel ... such fun

[HarryMann]

Yes, all can be a bit awkward but worth the trouble to make it airtight/leaktight and going in the right place... at least you're pulling fresh cool air in and filtering it properly. That really is No. 1 for TD diesel...

Then look at those other things...

[choplee]

back from my little camping weekend....All symptoms are the same struggling on pull off on any incline ,as i can just get her reversed up my drive without slipping the clutch to burn out ..lol... We do get up the inclines in the end ,but some can be long and noisy (and slow).
The airbox....i have the flex coming down from the rear side vent ...I have nothing coming of that ,but thats because my square airbox slides right in there .. .. It's a 2.0 airbox i have now been told ,but it isn't directly connected to this flex,so i'll try and get that sorted if the space allow it...Unless i can find an airbox to go back on this engine ...
still think a good setup and tune up etc...is needed ,so my quest to find someone in my area to do this goes on ....

[peasant]

This is the airfilter from a 2.0 Aircooled


This is what goes into a non-turbo diesel

Which superficially looks the same


this however goes into a turbo diesel

spot the difference?


I think that's your problem right there ...wrong air intake (air box)

That big barrel on the left with the yellow sticker ...that's the air box you need


and here is where you could get one ...choice of three for under 20 Euro
http://shop.ebay.de/?_from=R40&_trksid= ... Categories