Golf MK1 with 1.6 TD (CY) --- Diesel race car project - page 1 - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• Golf MK1 with 1.6 TD (CY) --- Diesel race car project by Alleslowbuged on 05 Feb, 2008 17:22
• 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
  
• #1 by Alleslowbuged on 05 Feb, 2008 17:40
• On the dyno run plot it is good to see, that there is not enough fuel above 4000 rpm as mention above.
  
  Here are some more pictures for anybody who is interessed:
  
  the original dynorun plot:
  []
  
  pictures, how i have buy it after ten years of down time:
  
  
  
  
  
  
  here the first intercooler (from a Opel Corsa 1.7 TD)
  
  
  the second intercooler (from a Mercedes Sprinter)
  
• #2 by Alleslowbuged on 05 Feb, 2008 17:49
• And here some actual picture:
  
  front view
  
  
  new instrument
  
  
  for me clean engine by with new spal cooling fan
  
  
  engine bay picture 2
  
  
  intercooler preparing for painting
  
  
  black painted
  
  
  new Ø256er brake
  
  
  changed mounting of the old cooler fan motor
  
  
  mounting for the intercooler
  
  
  intercooler mounted with water cooler
  
  
  change design of radiator grill (total)
  
  
  change design of radiator grill (detail)
  
  
  and i'am at 1:30 in the night with a dirty bonnet after much of work in a very cold garage    P.S. I'am not wilson from Tool Time:D
  
• #3 by Luv My Volkswagen on 06 Feb, 2008 10:40
• Nice car  
• #4 by Wolfsbur on 06 Feb, 2008 11:41
• Damn sweet MK1!
  
  'Whoosh Tish' of a BOV?
• #5 by Alleslowbuged on 06 Feb, 2008 15:15
• Hi,
  
  Wolfsbur, sorry but i don't know what "'Whoosh Tish' of a BOV?" means.
  
  As i mention bevor, i am planning to do a lot of modifications in the next time. Main is the swap to the AAZ base for increasing the cylinder capacity up to 1.9 ltr.
  
  As Fuel pump i will modificat my stock AAZ pump with parts from a VP37 pump from a 1.9 TDI called AFN with a Ø10mm plunger and 3.7mm stroke disk, beacause i will run max speed up to 6000rpm i will also modificate the speed/startin output adjuster, for more adjusting range.
  I think the original adjusting range is only for max speed of approx 5400 rpm, will mean 24° crank (increase to 30° crank)
  
  Also i will change the manuel boost controller to a electronic HKS EVC II and install my water/methanol injection. In the moment i have install the water/methanol injection in my BMW E28 524TD after the intercoller, regarding to the manufactor refernce, but be not sure if that had be the cause for two head gasket failures. So i will install it in the Golf Mk1 bevor the intercoller and only use for boost levels above 1.5 bar.
  
  I search for a impac momentum manifold, a 2.5" downpipe and perhaps for a nice inlet manifold, like that one from Passengers Diesel. So if anybody have these nice think for sell, i would be happy to get it offered or to get i tip, where i can get these parts.
  
  Best regards, Alleslowbuged
• #6 by Baselyne on 06 Feb, 2008 16:49
• nice wip, I love the german styles...
  Good luck
• #7 by Alleslowbuged on 20 Feb, 2008 15:50
• Hello,
  
  some new part has arived, so i get my new cluth, is for the 02a tranny.
  Means it is Ø228mm, clutch blade has torsion spring and 8x sintered metal pad, pressure plate is a reinforced sachs.
  
  I also ordered special tranny fastener, for mount the 02a tranny in a MK1, from a guy from the mk1 forum (golf1.info), which are also needed to use a mechanical clutch cable.
  
  The clutch should be able to handle 500Nm, so no problem for my "little" diesel engine. Here is a picture from the clutch, i am still waiting for the fastener.
  []
• #8 by burn_your_money on 20 Feb, 2008 15:57
• :shock: that windshield washer reservoir would last me like 2 years, that's nuts
  
  Very nice looking car
• #9 by speedy on 21 Feb, 2008 00:46
• Guess you can't have too much intercooler, eh?  
  
  Welcome to the board!  If you haven't found out already, many of the maniacs on this board are running 2.0 bar boost or more.  What's stopping you?  :-)
  
  -David
• #10 by Alleslowbuged on 21 Feb, 2008 15:49
• Hi,
  
  you are right, intercooler can't be big enough.
  
  i have get my mk1 out of road, a few weeks bevore, because i have buy my 1.9 AAZ engine and wand to swap. Bevore that i allways wand to run my car also for everyday life and so i try to leave it fail safe.
  
  Also pure boost don't bring you power without more fuel. As i describe bevore i had run the stock mk1 fuel pump first and then a change to a stock mk2 fuel pump, with housing firm idle speed adjustment. But in both case with very small and soft hub disk and and Ø9mm plunger. Short before i get the mk1 in my garage, i installed the better boost pin and stiffer spring for it.
  
  But anyhow with that fuel pump setup, in my mind it makes no sence to increase the boost level up to 2bar, because it is very difficult to become fast enough, the needed fuel amount, to use all the air. And if you are not fast enough, you will grill your turbo without much more power, because a big amount of the fuel will burn, when the piston is short before botton dead center and also later.
  
  I'am not sure if i have write that bevore, but i have a VP37 Pump from a MK3 TDI (AFN) (3,1mm hub disk, and Ø10mm plunger) here and will use that high pressure parts in my old IDI Pump housing. Also i planed to modify some more parts, to get max. spped of 6000rpm.
  
  I will use this modificate pump first in my still installed 1.6 engine for testing and first adjustmend, that i not have to start my rebuilt 1.9 engine, while beeing not sure if the fuel pump will work. When the 1.6 engine will have that pump installed, i will increase fuel and boost level so long, until the first part will give up (headgasked, tranny) or my stock mk1 turbo is at his end.
  Keep you informed :shock:
  
  So, i hope you can understand my poor english
• #11 by madmedix on 21 Feb, 2008 20:21
• Nicely done  
• #12 by Alleslowbuged on 25 Mar, 2008 17:15
• Hello,
  
  even we have winter here since a week, i have my mk1 on the street again for 5 days, for bring it in my garage. I have done some fine work mainly on the cooling system, because one hose had a leackage, but now everything is fixed.
  
  Before i start to ride with the car, i have tried to get more fuel out of the pump, but did not work so far. Anyhow i also increase the boost level after reading all this amazin boost levels here in the forum.
  
  I have run with max. 1.4 bar, but did not get much more power because fuel amount at higher rpm's is too low. I can see in the driving mirror how the smoke decrease with increasing the engine speed. Even with 1.4 bar boost instead of 1.0 before, i did not more power. I have read somewhere, that by increasing the idle fuel amount, the max. speed is automatic decrease due to the design of the governor.
  
  Here are some g-tech pics, the black one is with 1.0 bar the red one is with 1.4 bar. The poor 1/4 mile time with 1.4 bar also regards to bad shifting from thrid to fourth gear.
  
  [/img]
• #13 by Alleslowbuged on 12 Jan, 2009 17:56
• Hi,
  
  unfortunately i have to scrapping this car, because the rear axis support was to worse. Anyhow, i have a new project it is also a mk1 and should be a used as race car (if it will ever run sometime).
  
  In the moment i am collecting parts and be very impressed from the finisch input here on the board. I will start with my old 1.6 TD, but will change the trany to a 02a type (ASD or CTN). Also i will use a special MLS headgasket (same like 53willy) with additional steam holes like the aaz. Turbo will be stock at the beginnig, but with a custom intake, so perhaps i have to turn the turbo.
  
  Here are some pictures from the new project, they are from may but it looks nearly teh same today. My actual probelm is the coupling flywheel, i have lightned it (say EVO II), but it has still mechanical contact, so i have to lightned it more (say EVOIII), so that the axial backface is on the same level on the outer and inner diameter.
  
  http://s702.photobucket.com/albums/ww24/euro-styler/
  
  
  
  Best Regards
• #14 by madmedix on 12 Jan, 2009 18:30
• Wow. Very nice and clean. Would love to have a perfect slate like that to start with. Roll cage would have to come out though. Keep us posted