Golf II GTD with 1.9 AAZ engine --- EVO II

[carrizog60]

glad to see its moving.
that adapter as a stronger look,it it cast steel?

[Alleslowbuged]

yes, both are cast

[Alleslowbuged]

Hi,

so here is what i finally have waited for (thanks Trev0rbr for the link):






The manifold has a separate flange for a Ø38 mm wastegate and a T3 turboflange. First impression is pretty good, all surfaces was plain and deburred, also it seems like "heave duty". Worse was that the 4 flanges (to the cylinder head) are so big, that they cause a collision with the inlet manifold. So for mounting the manifold on the head, i have to grind the 4 flanges to fit with the inlet manifold (i used the stock maifold as sample):








( i must also grind the two inner flanges, later)

Here as it looks bolted together on an old head (... very practical to have an old head available)






The thread for the egt sensor comes in the T3/T25 adapter:



After mounting the manifold including the wastegate i have to recognize that the wastegate collide with the
driveshaft, that was the point where i stop for today.
(sorry for the bad pictures)







I have also dismount the PU inlets in the engine bearing, becuase i stll have had bad vibrations with the inlets
installed in the engine bearing.

positiv: i hope do solve the wastegate issue soon and think that the turbo will fit in the engine bay without problems
negativ: i have to cut my downpipe again, because the new manifold has a slightly different angle.

Best Regards
Alleslowbuged

[carrizog60]

how are you going to re-locate the WG?

i also have some vibrations at idle caused by a filled with windshield glue engine mount...

[Alleslowbuged]

Hi,

just as short notice, it is running again.
Details came later.

Best Regards
Alleslowbuged

[RabbitJockey]

Come on!!!!!!!!!! 

[Alleslowbuged]

Hi,

as posted, i could restart the golf last night and drive it home.
As hoped i could fixed the wasetgate issue, by removing the 90° adapter and the counter flange.
In sum this increased the gap to the drive shaft enough, so that it is ok know.



As result the wastegate is know 90° rotated regarding what i have sheduled, but the actual position is better.
(i must cut and reweld the wastegate pipe twice and it is still open at the end)
  


Because the stock air filter pipe did not easily fit with my turbo, i swap to a aftermarket filter. And because this
has no conection for the blow-by hose, i have also installed a catch tank. Here are the first pictures from yesterday:







On the other side of the turbo i have also cut and rewelded the downpipe, which needs a bit time.

Here it is all together again:




Today i have build a support for the new air filter:


I have paint and installed it, but forget to make a picture.
After that i first checked the static timing, which was with 0,88 mm - 0,89 mm quite good and second i checked
the internal pressure of the injection pump. I measure 2,0 bar @ idle and max. 5,5 above 4000 rpm, than i increase
it a bit to 2,5 bar @ idle and max. 6,0 bar above 4000 rpm. I found also that the pressure increasing is realy realy
slow, much slower as i exepcted and also much slower as in my BMW pump. I wand to have a max. pressure of 10
bar a 6000 rpm (same as my BMW pump), but could not adjust it, i assume that either the pressure control valve is
broken (due to my past maloperation) or the leakage at the timing pistion is to high. I will dismount the valve and
take a look at the spring, than i will know more.

As last step i turn the fuel screw 90° in, which noticeable increase the power and make the the car a bit smoky now
(before is was maximum a little bit grey). I would assume that it has a bit more power know than last year.

Best Regards
  

[Alleslowbuged]

Hi,

i was on the dyno this morning, it is more power than before.
However i did not make any changes in the last days, so i still see a bit of fine tuning potential regarding the pump setting.
Actual i only know hp figures, but i will put that in my excel spreadsheet and come up with my diagramms and numbers this
evening.

Best Regards
Alleslowbuged

[carrizog60]

.9mm isnt on the low side?
i use 1.00mm as static timing.
as far as slow dynamic advance maybe is the spring that iss too strong?

[Alleslowbuged]

Hi,

here as start the original dyno plot:



in numbers:

   139 kW (190 hp) @ 4446 rpm
   345 Nm             @ 3661 rpm

And here (as usual) my excel diagrams:
(if someone wonders, i have offset the purple curve - 200 rpm, because all dyno runs were carry out up to 5500 rpm on the rev counter, and all the bosch dyno measures directly
the rotating speed, but the dyno from the lila curve must manually "quick calibrated" for my runs.)





As stated before, spooling is rather ok since i have added a bit mor fuel. As could be seen on the dyno plot it is even better than with the T03 turbo.   
Due to the newly power increase, i would assume that my camshaft theory as limitating factor was correct. Except of a bit worse run just after cold start (due to less compression ratio), it feels better from idle to redline, whichs is in my eye mainly caused by the camshaft.

@carrizog60
The static timing of ~0,9 mm ist the original VW value, i kow that most people like higher values, but my own experience is, that this has realy bad impact to spooling of the turbo at low speeds. I prefer stock static timing and increased dynamic timing, my will is to have a timing from late at idle to early at redline.

The slow increasing speed of internal pump pressure is not affected due to the timing spring.

Best Regards
Alleslowbuged   
 

Gruß Alleslowbuged

[MJF]

Nice, next time 200hp?

[BillyWillicker]

VERY nice!  That turbo looks larger than a GT20 size, is it?  Where abouts does that big of a turbo "hit" in the rev range on the AAZ and how is off boost performance?

[carrizog60]

good to see that you got nice numbers!
were that hp figures what you were expecting?

[RabbitJockey]

So with proper advance at higher rpms it looks like breaking 200hp is not far off awesome numbers regardless especially considering you are not happy with the pump and you still have the stock intake and intercooler

And yes his turbo is quite a bit bigger than any gt20

[baldone]

nice