Finding 130 HP on a 1.6TD - What would YOU do?

[vanbcguy]

Well here's the challenge... You want 130 HP on your 1.6TD... No more, no less.  No interest in building the thing to support 150+ and the costs that go with that...

Why 130 HP?

Seems a nice "safe" number for stock parts, relatively safe for a stock-type clutch, safe for an 020 transmission...

What's your "Magic Formula" to get there?

[RabbitJockey]

http://www.vwdiesel.net/phpBB/viewtopic.php?t=18876

[vanbcguy]

Yup, good dyno run... Now all we need to know is what was done to the engine!!  I know he's got a Giles pump on there...

[Smokey Eddy]

i THINK my engine makes 100 or so give or take compared to my parents 90hp tdi golf...

And i have the fueling set to max on a stock pump with a bov/wastegate delete T3 with a ported&polished aaz head on a 1.6 block.
2.5" dp & straight exhaust to the rear tires.
It makes 25 psi pretty fast.

Intercooling would increase the torque significantly with those psi numbers.

With a giles pump & big nozzles im sure it would be over 130.


So, basically porting and polishing makes a huge difference i find. that + the aaz valves are significantly bigger

[barrygti]

Does the stock 1.6td pump have a limit for power?

I am sure you would pick up a ton of power with an IC yes.

I am aiming for around 200bhp if I can with same combination as you but larger turbo and an IC, just hope the fuel system can cope.

[Smokey Eddy]

I believe for those numbers you'll need water/meth inject and ... phew... 200... you'll need a big turbo for that i think ...

[Smokey Eddy]

perhaps even a compound set up....

A good compound could keep the car boostable under normal driving AND get you that high CFM with the big turbo to get the high hp numbers.

[carrizog60]

smokey i found 100hp too low for your setup...
with stock exhaust,stock pump otherwise lda pin cuted and smoke screw,k24 with closed wg doing 30psi and big i.c. in front i made 136 crank :idea:

[BlueMule]

Hello, first you need to flow 18 Lbs per min of air, then you need the fuel for the right mixture. So theoretically, 20 psi at 4800 rpms, with intercooler. This means that your compression ratio will be a whopping 1034 PSI, that is if the engine is fresh. Just to give an idea @ 10 psi boost 736, and at 6 psi 617. So you need some good fasteners to hold the head and rods together. Also cleaning up and peening the rods, crank might help to give more longevity.

A main girdle and head girdle would help, as would forged rods and crank, Also don't polish the ports and runners, just match and clean the casting up.

Blue Mule

[vanbcguy]

i THINK my engine makes 100 or so give or take compared to my parents 90hp tdi golf...

And i have the fueling set to max on a stock pump with a bov/wastegate delete T3 with a ported&polished aaz head on a 1.6 block.
2.5" dp & straight exhaust to the rear tires.
It makes 25 psi pretty fast.

Intercooling would increase the torque significantly with those psi numbers.

With a giles pump & big nozzles im sure it would be over 130.


So, basically porting and polishing makes a huge difference i find. that + the aaz valves are significantly bigger

So you're pushing 25 PSI with no intercooler?

I've been afraid of going over 15 PSI without one thus far... Highest I've ever done is like 16 or so.  I don't have an EGT gauge yet so I've been hesitant to push it any harder than that...

With the K24 I know I should be safe to 20+ from the turbo's point of view, but it's always tough to convince yourself to POTENTIALLY blow something expensive up...

[jtanguay]

with a bigger downpipe the EGT's are really reduced.  the less restriction on the exhaust, the better the efficiency.

[AudiVWguy]

What I did on this engine wasn't any big deal. I just addressed each component and tried to optimize each one the best I could with what I had to work with.
The block is a stock NA block.
The head is from TopLine. Port-matched, ported and polished. Intake- 180 grit, Exhaust- smooth and shiny.
Intake manifold: G60  ported and polished to 180 grit  (one of these is for sale,hint hint)
Metal head gasket.
Intercooler from a Mitsubishi Starion 2.6 ltr.
Water/meth injection.
8 lb flywheel.
ACN Trans.
Giles SuperPump
273 injectors
The Turbo: This is a reconditioned Roto-Master that came with the Callaway turbo kit. Intake and exhaust side has been ported and polished. The specs are in my Bently, which is MIA right now. This is a fairly large unit, meaning it takes a while to spool, full throttle-10 psi @ 3000 rpm. This has no waste-gate, so as much fuel as you can throw at it, the more psi. I limit it to about 20 psi.

The future for me is to try a different turbo. I have a Ball Bearing IHI VF14 off a Japan spec Subaru Legacy. This 2 ltr makes 280 hp at 7000 rpm. Hopefully this will help my torque situation.

As you can see, nothing here is any big deal. There are many of you out there who have some real torque monsters. 1.6 with an AAZ head seems to be a great combination of power and economy. Think of the motor as a pump, and anything you can do to make the pump more efficient the more HP will be a benefit also.

I hope this helps your future projects.
Cheers,
-JB

[TurboJ]

How does the 8lb flywheel work for you?
Any idle problems?

[foxracer1]

I have an 8lb on my car and it idles fine. a little more finicky on taking off but once the clutch is engaged no probs. Revs alot quicker. I have a 9A close ratio trans so the quick revs make it fun to drive.

[AndyL]

Following along with great interest; as I was about to post a similar question (though my goal was ~120hp) Only difference is I'm looking for the power down low in the RPM band.

My initial thoughts/reading were pushing me along the lines of using the 1.6 bottom end with a 1.9 head, 2.5" exhaust with a big IC - hadn't figured out the turbo yet... But then there's a problem of it does get cold here, and I'd rather the truck started in the winter - the lower compression from the 1.6/1.9 frankenmotor isn't going to help - today was going to be a day to call around and investigate if a local shop could decrease the size of the CC in a 1.9 head...