~91 Jetta gas GLI converted to a 1.6 turbo diesel build up~

[53 willys]

Clutchnet.com race sprung hub clutch and lightened flywheel

pretty much got everything ready now!!!
this here is a beautiful thing!!!!

kinda cleaned up engine bay...I still gotta gut the stuff I dont need out og the harness...

got my new gauges installed too!!!

 

[GOT-Torque]

Lookin' good...

 

[Billysgoat]

Niiiice....

 

[53 willys]

Well I made some exhaust this week..I spent about $200 total for the 3" mandrel bent turbo back system.
of coarse all the labor is me witch is the only way I can afford my projects

it not a tig welded SS down pipe....but I am kinda proud of this one.

painted with some 1500* flat.......yeah I know it will probably burn off.. but the same stuff lasted over a year on my cummins....

downpipe

downpipe connection

over the axle arm

4" gloss black turndown..

 

[53 willys]

engine in!

G60 valve cover back from powdercoat

glow plug relay base..

glow plug wiring...in place of old ECM...

 

[Innovative]

Great job so far. The VW TDI's are excellent commuters. We have an 02 and 06 Jetta. Both are Auto's. I have injectors and tuning on the 02.

I've been thinking about building a 2 Door Golf to have some fun with! :Cheer:

 

[UpstateDiesel]

Looks Great! I'm hoping to do some exhaust work on my '92 Jetta ECODiesel soon and open her up. Chris

 

[53 willys]

Update

well I did not make my goal I had to start it this week....I probably could have but I worked some other stuff on the car and not just the "get it started stuff"



I did most the glow plug wiring....I used Vince W's write up to get the idea on it but I went with a different style fuse block.
I have all the wiring hooked up to a VW style glow plug relay..then it's ran through the ford style relay and then to the fuse block, then to the glow plugs....




here is my glow plug wiring

 

[53 willys]

some pics of my water and oil supply lines..

turbo coolant return line hooked into the old oil cooler line...

turbo coolant supply line..

this is my "connectzilla" bonus points if you can tell what I made my oil manifold from :lol:
I have a few things hooked or will be hooked up there that why I have the manifold..OEM oil temp sender, OEM oil pressure sender, turbo supply..then I will have one extra spot for a incab oil pressure gauge or just a pressure checker spot for my shop gauge. (yeah I know I dont have the oil cooler hooked up in this pics....I still debating on if I should use the non thermostatic sandwich I have or ..just buying a new thermo version)

 

[53 willys]

I cut some of the lip off the front bumper so I could mount my intercooler on the bumper..

this idea is Zukgod1 idea...another big thanks to him for all his help and advice with this build...
this is a dodge cummins fuel canister/water separator

water drain

 

[53 willys]

new engine bay pics...

air filter tubing...

 

[53 willys]

how it sits now....

turbo diesel badge replaces the "jetta GLI" badge :twisted:
thanks for the badge Zukgod1

 

[GOT-Torque]

Looking good, should have it on the road soon...

Your oil line adapter looks like a 3 way splitter for an air hose connection. (what do I win?):hehe:

 

[53 willys]

Looking good, should have it on the road soon...

Your oil line adapter looks like a 3 way splitter for an air hose connection. (what do I win?):hehe:

yeah I hope to have it on the road next week...:st:




Nice job on the guess!!!! you are the winner!!!

I dont really have a prize....but if you want to send me your address I will send you a Uinta diesel performance sticker:Cheer:

 

[nomercy]

mark you are a true diesel guru if you can mod a jetta you are indeed a bada$$

 

[53 willys]

well I got it running and driving.......problem is when I pulled it out of the shop last night to drive it.

I go around the block 2 times...on the 3rd run the heater core blew open and filled my car with coolant

the other problem is it feels like I am not getting into 1st gear...the shifter is all the way over but it feels like 3rd when I take off...maybe my trans linkage is out of adjustment???

pretty bummed about it....I wanted to have this car done this week.....



here is a few shots of the single round headlight conversion I did (smoked E-codes).....I made/converted my square headlight radiator support to a round.....it was a PITA!!
also you can see my intercooler piping...

adjustable intercooler bracket

 

[UpstateDiesel]

Those Heater Cores are a Biotch! I did one at the end of the summer. It is a lot of tugging and such. Looks Good! Chris

 

[Billysgoat]

Don't you just hate it when everything goes right.............just to go wrong?

At least it's together and driving, that's something!

 

[6BT2500]

heater cores are fun dash has to come out and the a/c box unbolted of the fire wall then the dam thing just sits in the box no screws or anything, and its much easier to buy the single round support than try to mod a factory

 

[Diesel Fanatic]

Damn nice job!!! Also, where is Uinta Diesel Performance?