1600TD Syncro power output

[binner]

Hi All

I have a 1987 1600 TD T3 Syncro in Melbourne Australia. It's a UK vehicle and was privately brought here in 89.

It's pretty rare here so i have a few issues getting parts. There are plenty of Wasserboxers but no other TDs as far as i know.

Anyway, the original engine snapped it's cambelt so it has had a JR engine put in to replace it. This was rebuilt and had a new head fitted approx 30k miles ago before i bought it.

It also had a new turbo fitted which was shipped out from Germany and the fuel pump was recalibrated/overhauled. It certainly has blue paint spots and wire locks in place to indicate something was done. I have receipts but not an exact description of what was done.

It starts and runs fine but the issue i'm having is determining if the power output is correct. I'm not expecting a rocketship but it is really gutless and runs out of steam even up the slightest of hills. I can't really hear the turbo spooling boost and it doesn't seem to have any increase in power at rev ranges when the turbo ought to kick in.

Being a Syncro and a camper (Autohomes) it is pretty heavy.

I took all of the hoses and the aircleaner off last weekend looking for splits and or leaks and i found a rubber tube/box on the inlet side of the turbo had a big split where it was held on by the jubillee clip. Of course i can't get the replacement part here so i thoroughly degreased it and made a repair with hi temperature silicon sealant and left it for a week to cure properly. It may not be perfect but it is definitely sealing. No improvement when i took it for a test drive tonight.

I replaced a few other hoses and checked everything else really carefully. The aircleaner rubber was also not sealing properly so i sorted it out and reassembled expecting an improvement but it seems the same as before.

The turbo is spinning as i ran the engine without the inlet house and i could see it, and it wasn't oily inside. It looks like new.

The engine does smoke a bit when cold and then sometimes when hot. Sometimes blue, grey and black if you rev it.

Any ideas on what else i should be looking for?

There is also a weird electric fan that sits inside the bodywork behind the rear lights that has a tube running to the inlet manifold. I replaced that tube and verified the fan runs if i short out its sensor. I don't really know what that is for? Some sort of cooling device for the inlet manifold?

There is also some sort of valve on the inlet manifold which is assume is to control the boost as you can put a screwdriver in it. Is that correct?

Anyway hoping that some more knowledgable TD expert can give me something else to look for or an idea of what to expect from a good engine correctly setup.

Also a parts person who could deal via email or online would be great if anyone could suggest one. My local VW expert has the ETKA details but they would have to get the part overseas also.

Cheers
Gary Cookson

[Simon Baxter]

Stick a boost gauge on it and see if it is producing any boost.
Syncro Turbo is specific to that vehicle.

[binner]

Took it for a bit of a run today and it does seem much improved, got more power in the midrange.

I will try sticking a boost gauge on it if i can get hold of one.

Cheers
Gary

[Hoss]

That valve you were wondering about is the Dump Valve. I wondered what it was and even my local VW van dealer couldn't tell me.

Just bought my first T25 with a 1.6TD engine (JX) so am learning myself. Justkampers.com do a Diesel manual that I have found very helpful in finding my way around the engine.

Good luck!!