THIS IS THE POINT IN THE PROCESS WHEN I ADMIT I HAVE NO IDEA WHAT I AM DOING

[vwjones]

I just put a GTD turbo diesel into a N/A 1981 VW rabbit.  I have been running on hope until now and I'm not sure where to go next.  Everything I know I have learned from this forum and this has been a grand experiment to say the least.  Anyhow, I installed the GTD, complete with intercooler, EGT, boost, and all the gauges that matter.  It does run great and has a ton more power than it did before.  Trouble is that i'm greedy.  My boost tops out at 10 and EGT runs about 1300 at 10 of boost. I would like to have at least 15 if not 20 lbs of boost.  I'm wondering if the fuel needs to be turned up or what else needs to be done.  i'm running a 2.75 inch turbo back exhaust and it doesn't seem right that the
EGT should be that high at a boost of 10.  Is this the time to turn up the fuel and do the governor mod? There is a slight haze of fuel if I floor it, but no black cloud for sure.   i've read how to make the 1.6  a faster car in the FAC's but I'm not sure what to do now.  BTW, i've timed the IP to 1.0 static and the EGT's run about 700 down the highway at 70 mph with my 4 speed.  Can someone recommend?  Thanks in advance.  I was happy with my lame gasser until I came here so you guys owe me.

[rallydiesel]

Turning up the fuel at this point is only going to make your egt's worse. Make a boost controller and raise your boost. Have you gone with a bigger straight through exhaust?

[vwjones]

yes, i have a cone filter on a 3 inch pipe and a 2.75 turbo back exhaust.  I though that turning up the fuel caused the Egt's to go down due to the increased amount of fuel.  Am I that far off?

[vanbcguy]

Yep, you've got it backwards... With a diesel more fuel = more heat...

So your boost is maxing out at 10PSI, that sounds like the factory setting...

Have you:

• Modified/changed/disconnected/altered your wastegate at all?
• Done anything about the BOV on the intake manifold?

Definitely want to sort out your boost levels before you start cranking up the fuel.  At this point all it's going to do is raise your EGT's.

Also which turbo are you running?  I'm guessing a K24 or a T3?

[vwjones]

t2 it is all stock so far

[gldgti]

ok, so we can tell a few things:

1) if your running the t2, you probably wont wanna bank on that turbo past about 15psi... (to be cautious)

2) you definately need to adjust the wastegate to allow more boost. bleeding some boost from the actuator line is arguably the easiest way to achive this - i just tee'd off the line with a vaccuum line T connector and use different lengths of 3mm vacuum hose to adjust the boost :-)

3) the t2 has a very small turbine outlet and will limit your hp in the end, and cause you to have high EGT's generally because of its restriction (when running in a "tuned" state)

[vanbcguy]

Once you sort out the wastegate on your turbo (I don't have a T2 so I'll let someone else chime in on this) you'll run up against the BOV on your intake.  Factory intake manifolds on the 1.6 have a blowoff valve that opens at around 12 PSI.  When it pops it vents all the boost back to the pre-turbo side of the intake.

If you're doing anything with your wastegate you should block off the blowoff valve somehow first.  If it opens before the wastegate of your turbo it is very easy to overspeed the turbo since it suddenly has no backpressure.

On mine I just cut off a piece of broom handle and stuffed it up the BOV hose.  More elegant methods include getting or making a blockoff plate or using a later model intake manifold.

[vwjones]

so am i correct in assuming that if i use a boost controller (bought one yesterday) the boost will be limited and I will no longer have need for a BOV?  Does anyone have a T2 out there that they have put a boost controller on?  I took a cursory glance yesterday and it didn't seem obvious how to connect it.

[arb]

More elegant methods include getting or making a blockoff plate or using a later model intake manifold.

I welded my shut with a scrap aluminum plug. You could probably JB weld it if you cleaned ALL the oil off the aluminum. Just don't use carbon fiber against aluminum. It creates a nice little battery.

[regcheeseman]

unscrew the screw in the middle and fit a M6 Allen head bolt about 25mm long - screw it down just tight. It'll hold the valve shut.

[macka]

you can always grab a VJ11 turbo from a sooby forester. It'll kick in a little later then the T2 but you can run more boost, and it isn't too big for our fuel pumps.

[vanbcguy]

so am i correct in assuming that if i use a boost controller (bought one yesterday) the boost will be limited and I will no longer have need for a BOV?  Does anyone have a T2 out there that they have put a boost controller on?  I took a cursory glance yesterday and it didn't seem obvious how to connect it.

Your T2 will have one or two hoses going to the wastegate can.  If it's one hose it's easy - that's the one you need to be working with.  If it's two then you need one of the Garrett guys to tell you which hose...

Do you have a link for the boost controller you got?  There's a few different styles that get connected differently.

[vwjones]

so am i correct in assuming that if i use a boost controller (bought one yesterday) the boost will be limited and I will no longer have need for a BOV?  Does anyone have a T2 out there that they have put a boost controller on?  I took a cursory glance yesterday and it didn't seem obvious how to connect it.

Your T2 will have one or two hoses going to the wastegate can.  If it's one hose it's easy - that's the one you need to be working with.  If it's two then you need one of the Garrett guys to tell you which hose...

Do you have a link for the boost controller you got?  There's a few different styles that get connected differently.

there has been a development since I wrote about the boost controller.  seems the T2 can be turned up via the threaded actuator arm.  You just disconnect it from the wastegate and turn it one revolution per 1 psi increase.  Anyway, I turned it up to 15 psi (which i have been told is the safe limit for a T2 on this forum) and it ran up past it's previous boost limit of 8, and much faster to boot.  the BOV activated 10ish so i still have to fix that.  Any one need a boost controller, let me know. lol  maybe when i get the BOV sorted out I'll find that i still can't make it 15psi and will need the boost controller after all.  I'm beginning to get quite an impressive collection of new parts that I don't need.

[myke_w]

also - don't run with the boost controller on very much, it eliminates air which puts you right back where you were = HIGH EGT

I wasted a head on one of my early builds leaving mine intact and only doing a few runs.

[vwjones]

also - don't run with the boost controller on very much, it eliminates air which puts you right back where you were = HIGH EGT

I wasted a head on one of my early builds leaving mine intact and only doing a few runs.

I THINK that lengthening the actuator arm just preloads the spring that allows air to bypass the turbo in the same ratio, but at a higher psi threshold than before, in opposition to a boost controller which allows air to bleed out into the atmosphere.  but i am open to correction