MK2 GTD 1.9 VNT History of a SWAP(s)

[Apsik]

Hello,

recently this forum was very usefull to me because I was building my TD engine. Now I hope that the battle is over and it will be drivable [surprises free]
When I bought my 2nd MK2 I decided to swap a 1.6D into my 1st MK2, after a year it was not enough and i bought 1.9 AAZ engine ... "good condition" and I've been "fighting" to run it properly for a whole year.

What I've changed already:
Turbo: KKK -> GT14 -> GT20VNT with custome vanes control
Crank shaft: TD -> '97 TDI incl pulleys
Head: compleatly rebuilded (valves etc. incl.  some porting)
Pump: 9mm -> 10mm
Injectors: JR fited with 261 nozzles
Intake: hidden with K&N filter
IC: Merc-B. C-Classe (fited in the only avaluable space in the MK2 front bumper) pipes 48mm stainles steel
Exhaust: free 2" stainles steel
Oil catch tank
80*C thermostat and some other minor mods.

If I would have the knowledge I have now year before it would have been much easier... but it wasn't.

The main problem was the crank wedge (long story incl. cam timing problems and valves hitting pistons) and it snaped this summer when my car was 1000km from home. Now the crank is replaced and everything is back in one working piece.

Some pictures:
- custom GT20 mount


- TDI crank shaft


- proper vanes control solution (thank you tintin - I've been thinking for 2 months how to make it as simple as possible keeping functionality)




-vanes control improved with MBC


-engine bay now:


-the car itself:



Now I'm crousing for at least 1000km after that I'll try to find a nice power setup. I think 140+bhp and 300+Nm is possibe ... right?

I hope the engine is finaly ready for some power :roll:

I'd like to know your opinion about my project and all suggestions and questions are welcome.


PS. Many thanks to Zaprzal (VNT and power idea), Trochim (10mm pump), Da-BRT (great injectors) and tintin (complicated vanes control)

[rallydiesel]

That's a thing of beauty.

[1slowvw]

Your car looks great man, love the blacked out intercooler, very stealthy. Would love to see a vid of this thing running.
Just out of curiosity how much boost are you running?

1Slowvw

[Apsik]

Your car looks great man, love the blacked out intercooler, very stealthy. Would love to see a vid of this thing running.
Just out of curiosity how much boost are you running?
1Slowvw

Video comes soon - as soon as I find cameda with audio recording (my rec video only)
Currently for crusing ~1bar (1,2bar in peak). But I have no idea about the proper boost for power setup - guesing ~1,4-1,5bar

And one more thing - I have to get rid of the 02O gearbox is way to short. In spring I want to build 02A gearbox with 5th gear from syncro when replacing it I think it will be a good idea to reinforce the crankshaft fixing:

[Audi80]

Hmm, I wonder how my pics have got there  :shock:  :?  :roll:

[Apsik]

Hmm, I wonder how my pics have got there  :shock:  :?  :roll:

Because in my opinion it's the best idea to reinforce the crankshaft
If you have any obiections I'll remove this pict immediately.

[MontanaGTD]

nice headlights! where did you get them? I want a set!

[zaprzal]

Hmm, I wonder how my pics have got there  :shock:  :?  :roll:

don't worry, it's just 1.9mTDI syncro project site and this guy (Ventil from this forum) have some nice diesel fotos on server

[zaprzal]

nice headlights! where did you get them? I want a set!

custom made. Only in Poland  

[Apsik]

nice headlights! where did you get them? I want a set!

custom made. Only in Poland  

Indeed m8
That's Bi-Xenon system on lenses in AutoPal Clear hedlamps. I build it myself.
http://img441.imageshack.us/img441/8803/mk2gtd231ck6.jpg
http://img256.imageshack.us/img256/1870/mk2gtd232gl1.jpg
http://img257.imageshack.us/img257/3685/mk2gtd238yb0.jpg

[DA-BRT]

Ah so it's running again? Asked for feadback on the injectors but I think the email didn't reached you.

I'm very curious about the power!  

[MJF]

My guess is around 170hp/350nm with that setup

[Apsik]

Ah so it's running again? Asked for feadback on the injectors but I think the email didn't reached you.
I'm very curious about the power!  

No the email didn't show up but as I said before "thank you for the injectors" great stuff man.

My guess is around 170hp/350nm with that setup

...and the boost suppose to be?? (~1,5bar??)

Dyno test not before the end of winter. But I'm very curious about the power.

[rallydiesel]

Can you explain the VNT control a bit? Does the throttle connection only open the vanes on full throttle? Is the other controller a vacuum can or from a wastegate? How is the transition from vanes closed to vanes open? Can you feel it or is it smooth?

[Apsik]

Can you explain the VNT control a bit?

ok... take a look at this picture:


Does the throttle connection only open the vanes on full throttle?
The throttle connection close the vanes and open them as well (increasing throttle = closing vanes, decreasing throttle = opening vanes - cable connection is stiff enough to work both directions!)


Is the other controller a vacuum can or from a wastegate?
That's preasure can, it comes from stock AAZ KKK turbo wastegate so increasing preasure = opening vanes (because of the spring it can do the job)

How is the transition from vanes closed to vanes open? Can you feel it or is it smooth?
Comparing to 1.8T 300bhp I've been driving recently it's very smooth (just like my G60) but you can feel a bit more torque increase @~2400rpm (only on full throttle) and you can hear very clearly that the vanes are close turbo noise is quite loud and typical (it'a also because of the location of a air filter)

Understand it like this: when I'm crousing and I accelerate full throttle it needs ~1sec to build the boost (0 to 1bar) but the torque does't 'strike' you like tuned 1.8T used to do.