Hi,
my name is clemens and i am from Germany.
First of all, it is very nice to see american guys to work with old german engineered Turbo Diesel (IDI) stuff, mainly in that crasy professional way i see here.
But back to me and my car,
i have a VW Golf Mk1 from 1981 since nearly 3 Years with the origional 1.6 TD engine called CY. Additionally to modification on the car i change a little bit on the engine setup to increase the horse power.
That the parts setup:
stock air intake filter
stock garret turbo
huge intercooler (600x300x78mm), is the biggest what can be mounted
in the front of a MK1.
stock cylinder head (not opend by me)
stock engine block and lower parts
Ø60mm exhaust pipe behind the down pipe with sport silencer from
Papmahl straigh from the eightees (in best condition)
Bosch DN0SD297 nozzles
The max. boost level i runned until now is around 1.2 bar (can be adjusted from the vehicle interior) with special cone and spring in the fuel pump (the tougher spring is for reduce the smoke). The diesel pump is
then fine adjusted for the injection rate and the starting output (0,88 bevor OT [Uper deadpoint?])
For cooling, i have add special cooling fan, 80° thermostat and a separate oil cooler (stock from the GTI). I have a Ø210 sinter metal clutch with a FF (old 020) gearbox.
I try to add the last dynorun, but wand to explain that there was a big mistake in the adjustment of the fuel pump cone, which lower the injection rate at full boost pressure, that occurs no power increasing by increase the boost level from 0.9 up to 1.2 bar.
Results: boring 100HP@ 3600rpm and 280Nm @ 3200rpm
(meassured with a G-Tech Pro) I have reduce the 1/4 mile time from 18,06s with dynorun setup down to 16,33s with actual setup.
So that is the status quo, the car is sign off and waiting for the swap to a modificate 1.9 AAZ engine i will build up in the next month.
Power in kW
Torque in Nm