Bay Window with 1.9 TDI engine -> READY

[Kai]

Which turbo did you fit? I want more power from mine.
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Think......

Don't sleep and drive!!!

[Wilfred]

Just an original turbo. You could use the 130 or 150 bhp turbo but just that won't increase your power.

The charge pressure meter requires a certain amount of pressure. This is easier to deliver for the bigger turbo. But once the right pressure is achieved, it will slow down the turbo so you net pressure won't increase. It's just that your turbo might live longer as it doesn't have to work that hard.

But to be honest, with the new turbo and with everything working again, I am very happy with the power now. 120 kph no problem!
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[Wilfred]

noticed today I had a small oil leak at the turbo. Turns out I just hadn't tightenend the oil feed properly, so it would loose a few drops every 100 km.

fixed it, and went for a cruise an hour ago. Runs smooth now!

(although I can hear a cv joint when cornering hard...)

have to keep a few in stock I guess!! :-)

better lower the fan, but I really dont wanna loose ground clearance. I am gonna search for some better cv's
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[Wilfred]

Last weekend, we crossed the entire country. Did some 450km with the bus. Had a lovely cruise, bus performed extremely well!

A pic for entertainment:
https://lh3.googleusercontent.com/y_R3qlmB6QigtXUOSqJ7Sgic0i8d9XrqjYwvzi-yUetJTdmOV7PEp79ocTV4nLGA1gvZ9jpg6uaN_pEeAZN34WOee_S3kQtU_wypRktfmihSyZ2ojvUWD7NJQLAFcV5AqloiPbxTcGHq2ZHYN0wP72CAdMyH1vLnL1CXdxAtpmywK_jrXMa3XCsfZB9unSojphsR5vJiktF0jajdESqOSeGnfMAxqHsEMupE7onCxn0Vrxr8t97--JXil1qulapn2kzqXf7cWcIWC3Uxurv9u1ZLuItGE3BK_V_i4GBRk3HCoXyKhBigjita73rmkILUmTEXaSOUmGyx9HswhLy0hnoOD-5mXqNXng5eTRX8btm30lrlrmi2DghRj42lWKDEIzQ06gcKs_BU3ojgs1L4trULHqWMvFtImKiTqFt6ItOyNZvb-_kM365TYBMq_CITUwqqzP_EauXZjB6lphSIQE7h6qoBPE34I4Paq1tP482itpGSoOqbOyiXZbiOxY0R1eVRgvXLHl52zjXa99vhr-hdUh9b9gOsN5pN362Th9w=w526-h935-no
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[Wilfred]

I still have a bit of an oil leak, but it is so small, I can't figure out where it comes from. Everything is a bit greasy and cause I dont have a lift, I cant properly clean everything.

So What you can do is keep an eye on fluid levels.
Engine oil: check
Coolant: check
Clutch hydraulics: check
gearbox oil... : Hmmm. How can you check this....

LEt me seee..... A see through filter! Now I can check fluid level at the blink of an eye! I was always a bit worried I would run out of box oil without knowing it, but now I can keep an eye on the fluid level.

Click

Note: the level shown on the pic above was during filling, so with about 1 liter oil. This is not the correct level yet.
Note 2: the top of the filter goes to the breather hose using a T piece.

Because the breather hose runs up high, I can fill it from the service hatch, so gearbox oil issue solved I think.
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[skirk]

Hi Wilfred

Glad all seems to be running smooth with you now. I have a question as my engine is now acting as yours did. Sometimes smooth and then cannot go as fast as was previously cruising. Now seems to be losing power on hills. Did yours act like this prior to your turbo failure ?

Cheers

Saon.

[Wilfred]

That issue is fixed an only occured on my first real drive. I didn't post it over here but the issue was easy and both stupid... I had the airflow sensor the wrong way around. I just put it in backwards. Despite the HUGE arrow on the black tube, I still managed to put in in the wrong way.

After that, the power was constant although not as good as it is now with the new turbo.

you should hook it up to the computer.

typicial causes: loose turbo hose, loose vacuum hoses or worn vacuum hoses or the N75 valve (regulating turbo pressure) is a common problem.

Hope you get it sorted.
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[Wilfred]

Yesterday my van scared the poo out of me! I went to my brother, a drive of about 6 km. When I got there, it smelled terrible and lots of smoke coming out of the back.

I jumped out, grabbed the fire extinguisher and opened the engine lid. Nothing...

no fire but lots of smoke. I started thinking maybe electrics melting...?

As it was dark the origin of the smoke was hard to determine. AFter a while I thought about breaks. Touched rear right wheel... Burning hot! turns out it was stuck.

It scared the poo out of me, but in the end the issue is not even that big...

Will fix it next weekend.
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[trev]

scary!! had the same thing happen on my beetle once. Luckily it was an easy fix

[Wilfred]

I think I have fixed the gearbox breather issue.

I kept the connection in the drain plug, which is now on top. I connected this to the original breather tube. I put a Y piece in this hose which goes up to the engine bay and end in an open cup so I can see it when I still loose som oil.

did a nice highway cruise of about 100 km last week, and no gear oil loss whatsoever.

Only leaky fluid is coolant now. 1 hose is just bad and looses a bit over time. Needs replacement.

Another issue is that I used a bad joint in the gearing sticks. I used 2, 1 very good and another crappy one. The crappy one has already so much play that shifting gets harder. (just 2nd gear though). I need to replace this but the joint is located behind the radiator so I will do this in the winter when the bus isn't being used anyway.

all in all I notice it takes at leas a year before all minor flaws are solved!
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[Wilfred]

since I now have a job, income and all, I decided to, finally, buy a modern daily driver. Picked it up yesterday. Of course it needs work. The alternator doesn't work. Already bought a replacement unit. I specifically wanted an Alfa Romeo as they are well known for their reliability and build quility! :shock: :roll:



only 138.000 km. (86.000 miles that is)!

This means the bus can go to sleep now, until the weather clears up!

Of course I will work on it this winter... nothing major though!
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[easy-does-it]

Nevermind that ghastly thing... What's the green thing in the corner?
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'76 bay going superfly TDI