Seat Ibiza 2.0TDI...project 300hp

[galaboff]

Hi folks,

my name is Ivan Galabov, I'm from Bulgaria and I want to share my project with you...
my car is '02 Seat Ibiza 1.9TDI ASZ with loong 6-speed gearbox.

Mods:
- Turbo Garrett GTB2260VK /orginally KKK turbo BV39/
- FIRAD +100% nozzles /orginally PD550, good for up to 220hp/
- Ported head with bigger exhaust valves
- Tubular exhaust manifold - stinless steel material - 316.
- D24 intake manifold, actually this is manifold from 6 cyl. engine,
but with some modyfications is good for 4 cyl. engine.
- FMIC intercooler /originally SMIC...really bad   /
- MAF sensor gone down in history...
- 63mm stainless steel full exhaust.
- Ceramic clutch
- Originally rods, were replaced with Rosten 'panchi' rods
- Upgraded camshaft is from Dbilas - 272° 9.8 lift

Now my car is almost assembled..
I have to find good wide TIP(turbo inlet pipe), coz stock one is too restrictive,
after that next step is Remap..I hope up to 2-3weeks to share here 300hp dyno 

[galaboff]

pics:
Dyno graphic with my old turbo/gt2260v/
158KW/wheels - arround 240hp at flywheel


My tubular manifold:


My turbo GTB2260VK modyfied to vacuum control

[ibizz]

with that setup i think you can reach 300 hp

here in portugal there some 1.9 asv , vp and pd with that numbers with similar setup

good luck with that torque machine

[galaboff]

with that setup i think you can reach 300 hp

Yes, with 2.5bar boost 

[ibizz]

not realy need that mutch boost

and i think not need firad 100 too

good remap

heres 1 sdi engine (direct injection, but without turbo)  with 64 hp from factory
that puts 270 hp in dyno

big turbo , big ic , worked admission , good remap , worked pump , and big injectors nozzles

make a search of portuguese ibiza diesels projects
i think you il find manny 1.9 ibizas with and closing that numbers

[galaboff]

Here one Bulgarian Cupra tdi...
http://www.youtube.com/watch?v=JP7-k3GZypw

[macka]

who made your exhaust manifold? Can I also see your manual vane controller in detail?

[ibizz]

but thats a cupra , mutch beter and prepared engine and already as 160 hp from factory ...

sdi from ibiza as 1y engine with 64 hp factory .. so im thinking mutch more glory reaching almost 300 hp with a 64 engine
that reach it with a modern engine that already as 160 from factory .

but good aceleration as that cupra


your  exaust manifold are looking good !

[galaboff]

Actually this is my current manifold, that one from 2nd post is my previous..not good, but my new man. is amazing, really good spool!





at 2011-03-07

[R.O.R-2.0]

pics:
My turbo GTB2260VK modyfied to vacuum control

hows the vacuum control work? would you mind sharing with us? theres been a few ways already discussed on how to control vanes.

[rumbling_caddy]

   Does a highly a modified TDI engine like yours spew out huge plume of black smoke under heavy load like high output IDI engines or is the fuel management so good that diesel burns cleanly over the entire operating range?

[galaboff]

hows the vacuum control work? would you mind sharing with us? theres been a few ways already discussed on how to control vanes.

to make VK turbo to vacuum you need 3 things from vacuum operated turbo - stop screw and Z imaging arm which is connected to vacuum actuator and vacuum actuator ofcource..
you need a welder too. It is not good explanation, but this is my language potential 

[R.O.R-2.0]

i guess you have a full TDI, so i guess you have all the electronics to operate a VNT how its meant to be. no cables, or waste gates operating your VNT!

[rallydiesel]

Originally the gtb2260k has an electronic solenoid vane controller.

[galaboff]

 Does a highly a modified TDI engine like yours spew out huge plume of black smoke under heavy load like high output IDI engines or is the fuel management so good that diesel burns cleanly over the entire operating range?

My tuner is best tuner here...he makes fuel management really good, there is a smoke only after 4000rpm,
 but huge is not a proper word