G-Teched my 1.6TD - Baseline Runs

[malone]

Why did you have to modify the firewall? Were you using the VNT-15 or something different? The reason I ask is because I'm doing the ALH swap into my 89 Golf and will be clocking the turbo up like yours was. I'll be using the stock turbo that comes with the engine (might update to the VNT-17 later).

I'm hoping to not have to do that to mine if possible.

As pictured, I was using the GT20 and ATP 8v turbo exhaust manifold, not the VNT-15.

The VNT turbo will clear the firewall no problem, however you may have a problem with it interefering the rear engine mount. This was a problem on a B3 Passat I've seen, a MK2 I'm sure, and perhaps a MK3. It clears a MK1 no problem because it has a side engine mount rather than a rear mount.

You can cut your rear motor mount to clear the VNT (and perhaps reweld it for strength) or just have a custom one made.

[malone]

The pd 130 and 150 are the same except for ecu and turbo. I will might have to mount marks turbo upside down to clear the intake manifold. I am litereally int he middle of port matching and polishing the intake to the head, and the exhaust manifold as well. The actual port design on the 1.9 head is a lot better and the intake side is much larger. However the exhaust on the 1.9 almost seems smaller, by like a mm. But to match the exhaust maniold I'll be taking that much out anyways. The head will be going to the machine shop tomorrow to get the valve seats ground and a couple other goodies. Hopefully it wqill be back at the shop here by wednesday or so and than I can reassemble the head with the heavy duty valve springs and race ware headstuds and 1.9 metal head gasket. Than A custom grind cam ****** and I'll throw the pump on and all the other powdercoated goodies and it will be rockin. Especially witht he 4 puck cluytch and 6 pound flywheel!

Yes, the PD130 block and head are virtually identical to the PD150. PD130 injectors are easily capable of 200-220HP but the nozzles can also be upgraded.

(For others to read:) The PD130 also has a smaller intercooler than the PD150. With a PD150 turbo + intercooler + ECU upgrade, the PD130 performs identically to a PD150.

Thanks for the update Dave!

[dubCanuck1]

As pictured, I was using the GT20 and ATP 8v turbo exhaust manifold, not the VNT-15.

The VNT turbo will clear the firewall no problem, however you may have a problem with it interefering the rear engine mount. This was a problem on a B3 Passat I've seen, a MK2 I'm sure, and perhaps a MK3. It clears a MK1 no problem because it has a side engine mount rather than a rear mount.

You can cut your rear motor mount to clear the VNT (and perhaps reweld it for strength) or just have a custom one made

Yeah, I'm going to cut the mount and get someone to box it in again for strength. That's why I'm rotating the turbo to face up.

[malone]

I decided to use this PD130 TDI intake instead of the SDI version.





Oil pan that's powdercoated black:


1st custom cam version:


That cam looks like it was used because it was recently tested in dvst8r's 1.6TD for around a week. Lower EGT and quicker turbo spool-up was reported. A second custom cam was already made and it performs even better. I'm going to run the first version for now so I can dyno it, measure EGTs, and then step to the next aggressive cam.

Windage tray installed:




Credit goes to Passenger Performance for making this possible.

More pics coming soon.

[Maarten]

Looks nice  in grey/red

[malone]

We got the 1.9 TD valve last week but it didn't come with mounting hardware. For those who are not familiar with 1.9TD valve covers, a simple nut & flat washer will not hold it down. Dave made custom ones and took some time but it turned out real nice.

[malone]

I personally dislike ghetto-twisting wires together (w/ black electrical tape) because it looks messy and seems unreliable. So this time I went to an electronics shop and bought terminals and a bunch of ring connectors for clean connections. Keep in mind that I will have up to 10 gauges with roughly 5 12v power wires, 10 12v lighting wires, and 15 ground wires.

I was told these terminals (pictured) are all connected to each other but it turned out they weren't, so I created jumpers to connect the terminals.

So far I've readied 6 gauges for the main instrument cluster and I've already used up 50 ring connectors (pink, pictured). I need about 5-7 more connectors.



Testing the gauge lighting that is turned on via the headlight switch (only six lights are connected in this picture)

[malone]

Downpipe that's halfway done for the GT20 turbo. Following up is sandblasting and powdercoating.



Engine bay in its early stage:



The intake tract is visible below the bottom left corner of the intercooler pipe. The conical air filter is pointed down & behind the passenger side turn signal in the bumper.

The aging coolant reservoir looks like a Brit's tooth so I may pick up a new one

The engine ran for the first time last Thursday and it sounded great. On Friday the car was driven on the street and after it returned to the garage we found oil leaking from the turbo oil return line. It'll be fixed tomorrow, Monday, and then hopefully the car will be back on the street for good.

In case anyone wondered if a 1.9TD head on a 1.6TD block will work; the answer is a YES.

[malone]

Here's a photo of the car when it first started up:

"Hi, my name is Erik and I'm a chronic smoker"

[Maarten]

Here's a light, have another one  :lol:

Why did you put a 1.9 head on a 1.6? From the things I've read on this forum I thought the ports on a 1.6head are larger  :?

[935racer]

Just the opposet is true! The exhaust ports and valves are the same size, but the intake valves and ports are bigger and have a much better shape. This complete with extensive head port work and manifold modification, including a pd 130 intake couples for some serious airflow!

[malone]

Although some people noted that the 1.6 head has better designed exhaust ports, it doesn't really matter in this case because the 1.9 head is ported the 1.9 head's larger intake valves also made it more attractive.

I finished the custom instrument cluster yesterday:

It looks much sexier in person, especially with lighting in the dark :eek: The lighting colour is OEM-style radioactive green, which I like. That's a MK1 leather-wrapped steering wheel by the way. If anyone has a "turbo diesel" insert for this style steering wheel, let me know.

I'm thinking of getting a GPS device to use as a speedometer and odometer. It's far more accurate than a factory in-car speedo & odo.  I also won't have to worry about finding a spot to embed a 3" speedo gauge (I couldn't find a 2 1/6" gauge with speedo and odo that I could install in my radio delete panel, but then again that panel is already going to be full).



Something like the above. If the device has a 'permanent' mileage log (999,999km limit) and it isn't insanely expensive, then I'm sold.

[fspGTD]

It's really coming along... great looking dash and thanks for the updates!

[Maarten]

Can you post more detailed pics of the 130PD intakemanifold on the engine?

That could be a nice upgrade for my 1.9  8

The dash looks sweet Where do you rung the tach off?

[malone]

Thanks for the comments.

Maarten, a PD130 intake from a local yard may cost around $100 to $150 USD, or less. The PD150 version is similar but the inlet is facing the opposite direction. I'll take close-up pics of the PD130 intake installed on the engine, perhaps tomorrow evening (Thursday PST).

The aftermarket tachometer is connected to this:

Click here for product page.

That Dakota device is wired to the factory "W" terminal on the diesel alternator. It's pretty simple to install but I haven't gotten to the RPM calibration part yet.