Project Turbo 1.9L 1Y Diesel begins...>

[Staley]

edit..
**ADDED MORE PICTURES AT BOTTOM**

I own a Audi/VW Performance shop in Houston, Texas USA and have this disease.. called "can't leave anything just as it is"

I bought my diesel Rabbit for $50 US and won't tell you how much that I have spent on it since... but it is a LOT.  

I love the car, and drive it to work every day.
I installed a new engine and pump.. so I can have a reliable mode of semi efficient transportation.

I have done the "govenor mod" that has been talked about here many times.. and it seems to help a little.  
Three weeks ago I bought a 8v turbo manifold from ATP turbo.com and this Wedensday I bought a
T3 turbocharger with a STG1 super 60 compressor, and a .48AR Turbine with a 10deg. clip.
Time to turbo the Rabbit.
I will post up some pics soon.

Last year I bought a lump of classic turbo parts and kits from some guy on
vwvortex which inclued an original BAE turbo kit and a Spearco one.
I have several turbo fuel enrichment pumps but was thinking about using the Spearco fuel enrichment module.

The T3 has a 14psi wastegate spring.. which leads me to my next question..

HOW much boost is too much on these engines?
I have some intercoolers laying around the shop so I will definately
intercool the setup.

here is a link to some early pictures of the Rabbit..
I have some more recent ones i'll post soon

http://www.bartuning.com/photos/rabbit/index.htm

[Dr. Diesel]

look at that enrichment module... always wondered how they did it! isn't that something?
14 psi is a good starting point. Don't forget, with diesel, you don't have to worry about leaning out and detonation!

[lord_verminaard]

Nice color choice, looks GREAT!

That engine is just too clean, almost not fair....  


Is the block you are using a non-turbo or does it have the oil-squirters in it?

That might cause some issues with more than around 15 lbs of boost or aggressive fueling.  Either way, should be a killer setup - Those BAE kits are really cool, wish they were still avaliable.

Great work so far, good luck with the rest of it!  

Brendan
84 Scirocco 8v
00 Camaro L36 M49

[janb]

I've heard (and seen) sustained boost over 17psi will eventually destroy the head.  This was in a Westy Synchro, lasted about 30k,  Rabbit will be quite alot easier on engine, but keep an eye on EGT, especially W/O td specific alloys in head, pistons and valves.  It is alway recommended to use a true TD for the application.  I have found them for around $125, but... usually $500-$800

janb

[QuickTD]

I've heard (and seen) sustained boost over 17psi will eventually destroy the head.

What was the nature of the failure?

[WishIHadaRabit]

I ran my 1.9TD with a pretty big turbo and no wastegate.
I was able to spool up 20psi at 3600RPM and kept that all the way to the rev limiter.
In my set up there's not much more power to be had above 18psi
(on a hot day no power above 15psi)
A bigger intercooler would have helped.

I ran this set up for 140,000km, no problem

note: I also had a huge oil cooler, that I recommend

[WishIHadaRabit]

I ran my 1.9TD with a pretty big turbo and no wastegate.
I was able to spool up 20psi at 3600RPM and kept that all the way to the rev limiter.
In my set up there's not much more power to be had above 18psi
(on a hot day no power above 15psi)
A bigger intercooler would have helped.

I ran this set up for 140,000km, no problem

note: I also had a huge oil cooler, that I recommend

[chrissev]

possible you might blow the head gasket with a certain amount of boost.  The 1.6s seem to be worse for that then the 1.9s though.

[WishIHadaRabit]

1.9's have a metal gasket that fits on the 1.6L (same thickneses)
no more gasket problems

[Baxter]

Cor blimey, you lot over there really did sh!t out with the interiors didn't you! that looks weird compared to the European ones!
And what are those rear lights about? they don't look right as they don't line up with the swages in the rear panel, why are they so big?
European ones up to 1980 had the nice small one like the cabriolet, I got s set of "postie" ones downstairs, orange indicators, red reverse light, can decide wether to put them on our '82 cab or not?

[janb]

I've heard (and seen) sustained boost over 17psi will eventually destroy the head.

What was the nature of the failure?

cracks all over the combustion face,
valve to prechamber  (Worst)
valve to valve (common, but worse)

basically was a test done just to verify weakness.  As imagined it is prolonged temps and pressures on an aluminum head.

[Staley]

Here are some pictures of the intake manifold and the ATP turbo 8v manifold.  
I bought the intake manifold on ebay.. it is supposed to be a euro tdi 110hp manifold..??
I'm not sure about that.. but at least it is a D port manifold to match my head.  

The turbo like I mentioned above is a T3 Super60 with a stg1 compressor
and a .48AR turbine with a 10deg clip on the turbine. If you look closely at the turbine you can see
the shiny flat spots.. on each blade.. that is the place where the blades were clipped. The wastegate is a 14psi spring.

I took the exhaust and intake manifold to Polydyn here in Houston and had the exhaust ceramic
coated (inside and out) and the intake ceramic coated on the outside and a heat barrier coating on the
inside kinda like a jet hot type coating.

I have ordered the downpipe gasket so that I can have a flange watercut in stainless.

It is driving me crazy standing here looking at these parts.. I WANT to get
them on the car! one thing at a time.. and I only want to do this once! LOL
catcha later
Mike

[lord_verminaard]

Wow... pure diesel porn...


Holy lord, that turbo is a monster!  You sure it will fit back there??

Brendan
84 Scirocco 8v
00 Camaro L36 M49

[fspGTD]

A few comments: Car looks great... love the color.  The 1.9lNA engine install also looks really clean!

That microfueler thing like Dr D says, is RARE.  Interested in knowing how it works if you ever disassemble it to rebuild it, take pics and post them!  Also, nice job with the ceramic coatings... that stuff really does help.

Re: target boost pressure - I ran 14psi in my 1.6lTD (with big exhaust, intercooler, and factory garrett TA0304B turbo) when I daily drove it for years like that, and there were no problems with that boost pressure at all.  In fact, I found with an efficient turbo and intercooler setup, increasing the boost pressure can actually decrease EGTs!

Since you are a turbo guy you might try and track down the compressor map for that turbo and calculate how efficient it is at your target boost and airflow rate, and make sure it's reasonable efficiency and not close to overspinning.  From the size of it though, and knowing it was BAE kit factory designed for a VW diesel, I doubt it will have any problems at 14 psi (maybe even could do more than that.)  If you don't have piston-cooling oil squirters, I would keep the max EGTs more conservative than if you do.  (Bone stock 1.6lTD hits peak of 1500 deg F pre-turbine EGTs... 1300 deg F post-turbine... so use that as a reference point.)

With a big exhaust and intercooler, chances are, if your turbo is efficient, you'll be smoking far earlier than reaching EGTs even approaching the stock thermal limit.  Good luck!

[Staley]

Jake,
I bought the BAE and Spearco kits intending to use them..
but I decided to use the micro fueler from the spearco kit
and sell the other stuff.  What do you think those kits are worth?