So I am well underway here with the TDI swap, waiting to get a transmission, gotta pull my engine out to get the pump and bracket to build the m-tdi pump and mount it to the tdi motor.
but upon thinking here, how will the waste gate work? How will the pump take its boost enrichment? There are nipples coming off the cold side of the turbo, was this to control the waste gate? or just to tell the ECU how much boost it was making?
What needs to be done to get it running properly in m-tdi form in an mk1?
now i believe the AHU tdi ran 12-14psi stock, so it should be ok just for now to get it in and running shouldnt it ?
The k03 works the same as any other wastegated turbo. On the AHU, there is a valve that is connected between the wastegate and the pressure port on the compressor that is controlled by the computer. The computer doesn't get it's pressure reading from here though, it gets that reference from the map sensor. The computer can control when the wastegate opens by opening this valve electronically. To run it as an mtdi, just remove the solenoid valve and connect the pressure port from the compressor directly to the wastegate. If you find that you are not getting enough pressure you can add a boost controller or bleed off a little bit of the pressure going to the wastegate. Make sure the wastegate is connected to a pressure line otherwise it might over pressure, overspeed and turn into a grenade. The ko3 can run up to about 18 psi.
For the boost enrichment on the pump you can either put a tee into the this wastegate boost line and run another hose up to the lda or tap into the intake manifold or piping and make your own pressure feed line for the lda.
we talked of this before,,,, i left ya a whoretex message.. but here is the deal... very simple...
add nipple to intake... this goes to pump and to your boost gauge.. once inside at boost gauge add another t to it.. this goe to say a air pressure regulator for say a air tool.. this you will add a nipple on both ends... other end goes to waste gate... and as discussed before.. set it for 18-21psi... below that you will get shutter...
edit.. looked at reply on whoretex... you must add nipple.. LOL... stock is in the ic pipe.. brass fitting from store.. you will need 2 more fittings for the air pressure reg anyways.. just drill/tap something after the turbo and add a fitting.. nothing on turbo to get the feed from..
see the regulator??? big and bulky.. BUT i can adjust it while driving... one day ill make a real mount for it.. but for now zip ties work..
also looking at my photo... manifold goes in 1 side.. then the waste gate side goes to wastegate and the gauge.. there brass t after the regulator..
either way works.. but incase you see that you know..
The k03 does have a nipple on the compressor housing, I will take my boost reading from there.
I think for simplicity sake, it will be non-intercooled for the first little bit.
For boost reading and wastegate control connections, they both should be taken from the intake manifold. Reason being that the pressure will be the least at the plenum of the manifold and greatest at the small end of the compressor volute.
If you take your reading/control from the turbo housing, you will actually be getting less boost than the gauge is telling you. It will actually be 2-4psi lower at the manifold than at the compressor. I have found that just changing where you take your gauge/control from makes a big difference in driveability and response on any turbocharged car.