Author Topic: Top hat for 1.9TD Passat (Read 4774 times)

TD Passat · « **on:** September 16, 2005, 09:18:48 am »

I am looking for a top hat so i can run a intercooler on my turbo Diesel passat. I have been told some VW's have this as standard but i am new to the VW TD world of tuning. I am looking for the tophat that faces the other way. Not the 90degree bend.

Any info in finding the tophat inlet will be great.

Also is there a cheap turbo upgrade from another VW/Audi.
I have been told a KKK24 is used on the early cars instead of the KKK14.

If anyone has info turbos fire away.

Craig

lord_verminaard · « **Reply #1 on:** September 16, 2005, 03:11:21 pm »

Ok I'm not the smartest guy in the world, but I am VW parts-certified- what the hell is a tophat? :roll:

Brendan
84 Scirocco 8v
00 Camaro L36 M49

vwmike · « **Reply #2 on:** September 16, 2005, 05:14:14 pm »

I think he's talking about the inlet on top of the intake manifold. I'm pretty sure it's one peice with the intake manifold on the 1.9. I have seen some that point toward the drivers side though.... I think they're from TDI's. And the K24 or Garret T3 off a 1.6TD is larger than the stock K14 that the 1.9's had....plenty of people have used that as an upgrade.

TD Passat · « **Reply #3 on:** September 17, 2005, 02:27:42 am »

Sorry about the discription (tophat). With the engine i usually work on and tune it is called a tophat. (Vauxhall C20 LET) 2 litre turbo.

I am looking for a TDI inlet pipe or is it inlet manifold in one??? Which car? I am looking for this so i can fit a front mounted intercooler, as with the original 90degree bend there isnt much space.

The upgrade i have on my other car is a KKK26/24 hybrid rated to 420PS.
Which is a Vauxhall.

What car will i find the KKK24 or the T3 on? I know now its a 1.6TD but what model and year(s) in the UK.

Thanks for the replies

Craig

DieselMonkey · « **Reply #4 on:** September 17, 2005, 12:52:26 pm »

Craig,

In our toolroom we regularly 'turn' tophats for an employee who races 2 stroke bikes. It sits in the cylinder head and by machining new ones you can raise or lower compression as you wish. Thats what a tophat is to me, but now I know what you mean.

I presume your car is UK RHD, so the intake points towads the air filter / drivers side. If you can get a 1.6GTD top peice, it will point the other way, like the one on my 1.9 TD in the image below.

The mk3 Golf TDi manifold was one peice and points the same way, although it sits slightly different. About 1/2" more to the left (centre) and striaghter. The AAZ manifold with 1.6GTD bolted to the top will leave the CCV 'puck' on the rocker cover a bit in the way of the inlet pipe, but its no big deal really.

I have several TDi manifolds, a KKK K03, a Garrett T2 and a Garrett GT15. All are re-built, immaculate and if you need a turbo, I would consider selling for the right price. I dont have a manifold to match the T2 however. K03 and GT15's are younger, faster spooling, and in my view, better than the older K14 and K24 they replaced. K24 is bigger and will flow more, but I have little experience with it. I want to get my hands on a Holset turbo, really interested and impressed with the technologies they use, but I dont think there is direct bolt on for a VW manifold. The lowest trims they manufacture probably wouldnt entertain a sub 2.5L VAG motor.

If you want a manifold to get your intercooler piped up, I could search the loft for a mk3 TDi part. I'm in the UK..... 1.6 inlet part will be hard to come across now.

Regards, DM

Maarten · « **Reply #5 on:** September 17, 2005, 01:42:14 pm »

Another option is to turn the piece around 180 degrees if you have a TD AAZ engine where the piece is not one with the intake manifold.

the small pipe towards the pump points the wrong way then but that can be solved with a longer line..

TD Passat · « **Reply #6 on:** September 18, 2005, 02:42:38 am »

If it is possible then turning the inlet pipe is a cheap solution. I am not wanting to spend money on this car but free mods to better performance is what i am looking for. I am just wanting to fit a intercooler so i can turn the boost up and run safer. I have also seen the guide in the Tech tips about altering the pump and turning the boost up.

Anyone run Nitros on their diesel as i have a spare kit which can be fitted sometime.

Craig

TD Passat · « **Reply #7 on:** September 18, 2005, 02:52:43 am »

Is there any UK VW breaker i might find the 1.6TD inlet.

Craig

Maarten · « **Reply #8 on:** September 18, 2005, 05:48:14 am »

A TD inlet has the same orientation as on the 1.9, you need the 1.6GTD RA of SB enginecode inletpipe.

This is a 1.9 intakemanifold:

The top part can be mounted 180degrees around.

TD Passat · « **Reply #9 on:** September 18, 2005, 10:10:08 am »

Ok will have a look at doing this tomorrow. Fitting a boost guage to see what boost it is making also tomorrow.

Is it best to use a cone air filter and remove the airbox or replace the original filter with uprated. Eg. (K&N)

Maarten · « **Reply #10 on:** September 18, 2005, 10:18:36 am »

A cone can improve airflow, I'm using a shielded conefilter to avoid sucking in water:

I'm going to put a piece of pipe between the filter and the stock hose to move the filter just behind the headlight so it sucks in colder air

ps. I just found a spare GTD "tophat" your looking for, it can be yours for 10 euros but the shipping would be too much I think.

TD Passat · « **Reply #11 on:** September 18, 2005, 11:14:21 am »

PM sent Maarten

TD Passat · « **Reply #12 on:** September 18, 2005, 11:28:26 pm »

Which inlet line is the best to fit a t-piece so i can get accurate bosst pressure on my boost gauge. Any pics.

Craig

Maarten · « **Reply #13 on:** September 19, 2005, 12:56:44 am »

The most accurate is the one to the wastegate, that is pressure directly from the turbo.. The simplest option is to cut the line to the LDA from the intakemanifold.

TD Passat · « **Reply #14 on:** September 19, 2005, 04:10:20 am »

Turned the inlet pipe around today but put it back to original position. Too much to change. I cleaned the inlet pipe and what i think is a blow off valve. This valve was nearly blocked off with thick oil.

Also fitted a boost gauge and is holding between 10-12psi. I connected into the actuator to turbo pipe.

What do i have to do with the pump if i want to increase boost to 1 - 1.2bar? Is this safe or is 1 bar the limit before installing a intercooler.

Craig