1.9TD project?

[xxkoadyxx]

I picked up another 1.9td and trans today.. This 1.9 has a ko3 turbo on it.. what should i do and get for this engine.. im looking to get more hp ouut of it.. any suggestions on what needs to be done? thanks. im looking for 150ish hp

[GEE-BEE]

Giles pump, intercooler is a must

Go to a Hybrid K03 or VNT or T3turbo will require a different manifold and will change to a different downpipe

[Alcaid]

Giles pump, intercooler is a must

Go to a Hybrid K03 or VNT or T3turbo will require a different manifold and will change to a different downpipe

Wrong, the '93 Golf should have the square 4-bolt flange on the downpipe, same as the T3. They didn't change downpipe flange until '94.

Don't remember if it has the triangle or the trapezoidal exhaust manifold flange but if it's the triangle one, a manifold from 1.6TD would make that turbo plug right in there, maybe some small changes to the oil feed/return and hosework.

[xxkoadyxx]

Giles pump, intercooler is a must

Go to a Hybrid K03 or VNT or T3turbo will require a different manifold and will change to a different downpipe

what is a hybrid KO3?

[GEE-BEE]

KO4 hotside with a K03 coldside

manifolds are different on T2/T3/K14 series versus K03 turbo

The Intake boot from Filter( snorkel) and turbo to intake manifold  is different also

Ask me how I know ?

or you can listen to Numb's nut's above...

GB

[xxkoadyxx]

KO4 hotside with a K03 coldside

manifolds are different on T2/T3/K14 series versus K03 turbo

The Intake boot from Filter( snorkel) and turbo to intake manifold  is different also

Ask me how I know ?

or you can listen to Numb's nut's above...

GB

the engine in my car right now is a 1.9td also but it has the k14.. inlet/airfilter side is alot bigger then the ko3, but i cant adjust the boost on the k14..which would be better?

[Thezorn]

but i cant adjust the boost on the k14..which would be better?

you sure can, all you need is a manuall boost controller in the line that goes between the turbo to the wategate. I have mine regualted to 15 psi and it works great.

[xxkoadyxx]

but i cant adjust the boost on the k14..which would be better?

you sure can, all you need is a manuall boost controller in the line that goes between the turbo to the wategate. I have mine regualted to 15 psi and it works great.

there is no line.. only a metal line. would that be it? looks like an oil line to me.. heres pic.....

[Vincent Waldon]

That's the one.   

[xxkoadyxx]

question, whats the purpose of a boost controller? stock the flow of air going through lines? if so cant i just sqweeze the line? lol

[Vincent Waldon]

That steel line is feeding back boost to the wastegate... allowing the turbo to regulate itself to the set boost level. A boost controller "tricks" the wastegate by showing it less than the full output... so the wastegate ups the boost accordingly.

Pinching the line would merely slow down the flow and thus the response time of the wastegate, but would have very little effect on the setpoint, since the wastegate would still see the same pressure.

[xxkoadyxx]

alright so that is the line.hmm ok so ill need to cut it,flare it,then add hose to it? boost gauge is a must.. whats max i should stay from with stock block.. only untill i get my other built..

[vanbcguy]

Nylon Home Depot tubing slipped over the cut off ends of the metal line... I ended up putting a zip tie around each of them as a hose clamp eventually.  Humidifier bleeder valve connected to the 'T' to bleed off pressure and hide it from the wastegate.

$5...  I keep it at 15, but have ended up a bit higher a couple of times by "accident"... It seems generally speaking 15 PSI is the most you should do without an intercooler - after that you are heating up the air so much compressing it that you are negating the benefits of higher pressure. 

My boost gauge is from Princess Auto and cost almost nothing.  Any pressure gauge will work!  I tee'd mine in to the air line to my LDA. 

[Alcaid]

NXT Boost Controller is 20$ on Ebay without the ghetto DIY look



You can eliminate the metal line all together by using banjo/barb fittings.

[R.O.R-2.0]

KO4 hotside with a K03 coldside

manifolds are different on T2/T3/K14 series versus K03 turbo

The Intake boot from Filter( snorkel) and turbo to intake manifold  is different also

Ask me how I know ?

or you can listen to Numb's nut's above...

GB

most of the time its a K04 cold side (more flow) and a K03 hot side (quick spool) that make up a K03 hybrid.. they do come both ways (obviously, as Mr. GB is running one of them) but it is said that the 04 cold side will make better results.