Fixmyvw.com

Author Topic: Golf II GTD with 1.9 AAZ engine --- EVO II  (Read 150633 times)

Reply #30August 08, 2010, 06:33:44 pm

Alleslowbuged

  • Veteran

  • Offline
  • ***

  • 270
Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
« Reply #30 on: August 08, 2010, 06:33:44 pm »
Hi,

today was racing time.

I was on a 1/8 mile race and get the first place in the diesel class "up to 150 hp" with my
good old fragile vw mk II. The track was a bit wet all the time, but on the third run it was
nearly dry and i could decrease my 9,7 s from the second run to a 9,3 s in the third run.

here a pic and three videos:








I am really happe with that result, because i was not even sure if i could be faster than last year with my bmw. In fact i have still only 0,8 bar boost in the first and 0.9bar boost in the second gear, which means not more than 0.9 bar boost for more than 3/4 of the complete track.

Best Regards
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #31August 09, 2010, 05:12:33 pm

TDIMeister

  • Veteran

  • Offline
  • ***

  • 284
Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
« Reply #31 on: August 09, 2010, 05:12:33 pm »
Nice!

Reply #32August 17, 2011, 05:48:12 pm

Alleslowbuged

  • Veteran

  • Offline
  • ***

  • 270
Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
« Reply #32 on: August 17, 2011, 05:48:12 pm »
Hi folks,

one year ago, that i last post here something regarding my mkII golf.
Beside a new pump mod to 12mm plunger and IDI camplate there was no big thing to speak about,
but here is the progress:

new exhaust, i only used the last muffler (group A, street legal):


mounted:


new dyno runs with actual pump:
@1,2 bar


@1,5 bar


here are power and torque curves in comparision to the old curves, the difference is 95% the turbo (old K14, actual T3)




here are some pics, with new vortex rear spoiler and new exhaust (winter tires with 25mm plates per side):






Than i have had a little accident, which bend the car body, but everthing could be easly fixed, here some pics:





just refit (before re-bend)
 


This was all only the past, actual i have dismount the cylinder heat again, which will be ported again to level two.
Also the valve seats will be machined, so that the valves will be approximate 1,0 mm deeper in the head, to exposing
more space for valve lift.  Due to the machining the valve shaft will be cut be the same amount, also the valve plate
will be cut by ~0,50 mm to expose even more valve hub.

Here is a pic of the dismounted head, which shows no cracs or something else due to my mistreatdment:


Best Regards
Alleslowbuged

   


 
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #33August 18, 2011, 12:44:38 pm

Alleslowbuged

  • Veteran

  • Offline
  • ***

  • 270
Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
« Reply #33 on: August 18, 2011, 12:44:38 pm »
Hi,

i also forget to mention, that i change the complete brake system from "GTD" to "G60", so i have now Ø280mm disks
on the front axle and Ø226mm disks on the rear axle plus 9" brake booster and 22er master brake cylinder. In fact this
means also that i need new winter tires, because minimum rim diameter is know 15".

Best Regards
Alleslowbuged

 
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #34August 18, 2011, 04:52:36 pm

carrizog60

  • Veteran

  • Offline
  • ***

  • 978
Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
« Reply #34 on: August 18, 2011, 04:52:36 pm »
glad to hear that the repair was easy.
why is your dyno having that loss of power at high rpm?

maybe is low boost but with k24 boosting 2 bar i hit almost max power at 4000 and then it increased only 5hp until letting off.
i had the wg blocked and the more rpm,the more boost.you should try as you have 12mm head.

speeking of 12mm head were did you sourced yours?
2 days ago i let a 11mm head go from ebay.de, and since you are from germany(i am from portugal) i would like to see if they are easier to find there...
vw golf gti G60--vw passat 1.9td gt2052v
yamaha vmax 1200- yamaha tdm 850
Portugal

Reply #35August 18, 2011, 05:31:09 pm

Alleslowbuged

  • Veteran

  • Offline
  • ***

  • 270
Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
« Reply #35 on: August 18, 2011, 05:31:09 pm »
Hi,

i did not know why high rpm power is lower with T3 turbo and 12mm plunger (IDI camplate) than with the K14 and 10mm plunger (TDI camplate).
Could be better advance timming of the pump or just higher boost pressure with the K14 turbo, as i now know that my previous boost gauge was
fully inexact and i therefore did not know old K14 boost pressure.

On my other car (BMW 524TD; E28 from 1986) i have also build and installed a 12mm pump (with other mods too) and have now peak power of
208 hp at 3200 rpm and peak torque of 480 NM at 2950 rpm. Before (stock 10mm plunger) i have had 200 hp at 4400 rpm and 360 Nm at 3000 rpm.
Here can you see both curves, red is actual one and green ist the previous, both has same turbo.





What is clearly seen is, that as better the pump work, as earlier you get the peak power. In fact for me both engines are limit in power due to
not enough air through the valves. That is also the reason ,why i dismount the head in the golf and why i will install a 260°/250° camshaft.
lift is 9,9 mm / 9,4 mm, timming is 18°/62° - 57°/13°, spread angle 112°, valve lift in TDC 0,50 mm.

I hope to expose high rpm - huge peak power due to that, because my pump is captable for that and also the turbo should be able to bring more
boost, if more fuel can be burned at high rpm. If the golf will show that i am on the right way, the BMW will follow in the winter.

Best Regards     
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #36August 18, 2011, 05:36:03 pm

carrizog60

  • Veteran

  • Offline
  • ***

  • 978
Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
« Reply #36 on: August 18, 2011, 05:36:03 pm »
why not to up the boost?
with a 12mm 1.5 bar from a T3 would be low for high power right?

where did you source your 11 and 12mm heads?what cost?
vw golf gti G60--vw passat 1.9td gt2052v
yamaha vmax 1200- yamaha tdm 850
Portugal

Reply #37August 18, 2011, 05:46:43 pm

Alleslowbuged

  • Veteran

  • Offline
  • ***

  • 270
Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
« Reply #37 on: August 18, 2011, 05:46:43 pm »
@carrizog60

i forget to speak about the 12mm head. I have bought a couple of 10 mm, 11 mm and 12mm head in last years, becausei allays buy
thoose things, if they are available, because i know that there are not available, if the need them. The used 12mm head is from a paket
of two complete iveco pumps i have bought in england serveral months earlier.

I still have one 11mm and one 12mm head here, without any using at the moment. I have also one 9 mm head (modern one from PSA), which
will fit TDI camplates plug and play, for building a 9 mm monster pump as comparision to the 12mm i used actual. So in fact i did not have any
easy source for good pump components, i just buy any if it seems a reasonably deal.

I have also have a 12mm giles pump (stage 3), which a have bought here and only used for servera days. I you or anybode else is interessted to
buy please PN my.

Best Regards    
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #38August 18, 2011, 05:55:35 pm

Alleslowbuged

  • Veteran

  • Offline
  • ***

  • 270
Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
« Reply #38 on: August 18, 2011, 05:55:35 pm »
Hi again,

i just read you post.

The 1.5 bar during the dyno was still measured with the old gauge, so i dont know real boost.
Since the dyno last autum i have always drove with no wastegate active (excluding longer trips on german Autobahn)
max. boost level is between 1,5 and 2,0 bar, depending on gear and load. But as i say, i am pretty sure that without
hardware mods on the head and on the valves, i can not countable increase peak power over the 165 hp i have had
with the K14 turbo. Funny thing without active wastegate is, that there is nearly no blake smoke with the actual setup.


Best Regards
Alleslowbuged
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #39August 19, 2011, 04:04:12 pm

vanbcguy

  • Administrator
  • Veteran

  • Offline
  • *****

  • 2831
  • Personal Text
    Vancouver, BC
Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
« Reply #39 on: August 19, 2011, 04:04:12 pm »
I really like the turndowns on your exhaust - wish I had something like that.  I have a dual outlet muffler but it shoots straight back, ends up getting my bumper sooty sometimes... :)
Bryn

1994 Jetta - AHU M-TDI - Jezebel Jetta
2004 Jetta Wagon - 1.8T - Blitzen

Reply #40August 20, 2011, 05:02:14 am

carrizog60

  • Veteran

  • Offline
  • ***

  • 978
Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
« Reply #40 on: August 20, 2011, 05:02:14 am »
same here,it get worse being the passat alpine white lol
looks like a train lol

what size is your outlet on the exhaust?

any news regarding pump swap?

you are going to try a S2 but why not a vnt?
with your pump and a gt25 that would be a tyre burner lol
vw golf gti G60--vw passat 1.9td gt2052v
yamaha vmax 1200- yamaha tdm 850
Portugal

Reply #41August 21, 2011, 11:08:32 am

Alleslowbuged

  • Veteran

  • Offline
  • ***

  • 270
Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
« Reply #41 on: August 21, 2011, 11:08:32 am »
Hi again,

i have thinked about vnt, but i am to concerned about to much low rpm torque, as i have only stock internals and wand to stay a friendly with the gearbox for a long time. I also heard a lot of people going vnt and have broken turbos with idi engines, and beside there is also the controling issue to solve.

After long time searching i found a S2a compressor and turbo map today and it seems like perfekt fit for my goals.
Here are both maps, i try to put in boost line (from squirrel calculation) and will post that later:

(i do not know which compressor type and wich exhaust ar i have)


Best Regard
   
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #42August 21, 2011, 01:57:56 pm

carrizog60

  • Veteran

  • Offline
  • ***

  • 978
Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
« Reply #42 on: August 21, 2011, 01:57:56 pm »
i had the same concerns that you have.
your problem is solved going big.
i chose a gt2052 and its not a quick spooler in the low rpm,but is faster than any wastegated turbo of its size.
for you i would go for a 22 or 25 series,no problem with low rpm torque.

for the S2 maps...sorry to say that i dont konw how to read maps...(info on a good place to go for learning will be great tho)
vw golf gti G60--vw passat 1.9td gt2052v
yamaha vmax 1200- yamaha tdm 850
Portugal

Reply #43August 21, 2011, 03:39:18 pm

RabbitJockey

  • Veteran

  • Offline
  • ***

  • 5061
  • Personal Text
    America, DUCK YEAH!!!
Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
« Reply #43 on: August 21, 2011, 03:39:18 pm »
compressor maps i understand, turbo maps i do not, i wasn't sure whether or not they even existed.
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #44August 21, 2011, 04:29:15 pm

Alleslowbuged

  • Veteran

  • Offline
  • ***

  • 270
Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
« Reply #44 on: August 21, 2011, 04:29:15 pm »
Hi,

as promised, please find attached both maps, now with my assumend boost lines for compressor and turbine:

I have first put all my data (data i would like to have) in the Borgwarner MatchBot and plot the resultant compressor and turbo maps
for an EFR-6255 turbo, than i uses the results and tranfer them to the S2a maps. How accurate that is, i don't how. In my mind i think
the biggest uncertainty is the volumetric efficency, which is used as input value in the MatchBot.

Next step will be to measure my S2A, to idendify the type. I am not to concernd about the compressor, as could live with both of them,
but i could imagin that my exhaust AR could be to small.



Best Regards


    
« Last Edit: August 21, 2011, 04:32:31 pm by Alleslowbuged »
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

 

Fixmyvw.com