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Author Topic: 1.6TD manual boost controller  (Read 1975 times)

October 05, 2022, 09:44:29 pm

oblique

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1.6TD manual boost controller
« on: October 05, 2022, 09:44:29 pm »
Hey folks, I searched but existing threads are pretty old and pics are gone.

Im dropping my pump off with Giles this week and need to tell him how to build it. My motor is stock and will remain that way. I told I can go 15psi max on a bone stock car but Iv got 210k miles so that seems like much. Does the stock blow off valve open at 12psi? Can I run the stock setup without an MBC if I get it tuned to 12psi?

Also how exactly are these installed? Does anyone still make them? If I didnt want to create one myself, etc. but purchase a kit.



Reply #1October 06, 2022, 12:05:50 am

fatmobile

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Re: 1.6TD manual boost controller
« Reply #1 on: October 06, 2022, 12:05:50 am »
You don't need a boost controller.
 From what I've seen you'd be lucky to get 10psi from a stock turbo.

 There is probably a blowoff valve in the intake.
 Most people block it by putting a bolt in it and tighten the adjuster down.

There is a guy on utube that shows how to get the waste gate to stay closed and get up to 25psi.

15 isn't too high.
 My VNT-15 gets there and keeps the EGTs down pretty good.
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #2October 06, 2022, 07:00:35 pm

oblique

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Re: 1.6TD manual boost controller
« Reply #2 on: October 06, 2022, 07:00:35 pm »
My understanding is that the more fuel you add, the more boost you generate on these cars. With a properly tuned pump (ie custom built to desired boost, not just turning the fuel screw) you can get the boost pretty high. By simply blocking the blowoff you can get into a situation of too much boost hence the manual boost controller.

Reply #3October 07, 2022, 12:26:22 am

fatmobile

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Re: 1.6TD manual boost controller
« Reply #3 on: October 07, 2022, 12:26:22 am »
I'm not sure that's true.
 Most people disable their blowoff valve and even disconnect the waste gate,..
and still only get 10psi.
 I think you can run it without a MBC,..
but I've never run a Giles pump.

Get a boost gauge and EGT gauge installed.
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #4October 09, 2022, 03:34:12 pm

oblique

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Re: 1.6TD manual boost controller
« Reply #4 on: October 09, 2022, 03:34:12 pm »
Lots of posts out there with folks running 30psi+ blowing up stock motors. I dont think its overly difficult to do, blocking off the wastegate and turning the fueling way up.

I asked him to built it for 15psi but shim it for 10 while I figure this out. Can anyone confirm the stock wastegate opens at 11/12psi? (assuming everything is working properly) The shim can be removed easily in his parking lot, apparently when Im ready.

Reply #5October 10, 2022, 12:50:07 am

fatmobile

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Re: 1.6TD manual boost controller
« Reply #5 on: October 10, 2022, 12:50:07 am »
I haven't seen any of those posts about blowing up at 30psi.
 I could see that happening though.
 I've hit 35 briefly a couple times using a wide open VNT-15 on a 1.6 with no problem.

 If you can get it to boost to 15 then do it.
Especially with the stock turbo that doesn't wind up until after 2000 RPM.
 From what I hear too much power at the low RPMs is what does the damage.
 
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #6October 10, 2022, 11:42:20 pm

fatmobile

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Re: 1.6TD manual boost controller
« Reply #6 on: October 10, 2022, 11:42:20 pm »
I wouldn't worry about over boosting.
I think your situation is going to end up more like this guys:
https://www.vwvortex.com/threads/exhaust-plumbing-mk2-1-6td-in-mk1-truck.9500182/page-3#post-115710362
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #7October 14, 2022, 06:42:48 pm

oblique

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Re: 1.6TD manual boost controller
« Reply #7 on: October 14, 2022, 06:42:48 pm »
Hard to say, he says he's running an eco pump w/o LDA...not clear if he turned the fueling up on his IP either.

I think with blocking the blowoff, modifying the wastegate and changing IP fueling (and/or custom building a pump) you can squeeze these stock turbos for quite a bit is my understanding.

Reply #8November 16, 2022, 09:42:25 pm

oblique

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Re: 1.6TD manual boost controller
« Reply #8 on: November 16, 2022, 09:42:25 pm »
So I bought a Garrett T3 from ebay..it was listed for parts so I thought Id play around with it. Anyway when I received it, sure enough I couldnt rotate it by hand but when I put a 3/8 ratchet on the cartridge nut and wound it back (ratched backwards to adjust the angle) that was enough to get it spinning. So I sprayed wd40 down the hatch and started working it...after a while it spun freely and testing the wobble it seemed really good. Very little corrosion on the body so Im thinking this turbo must have lower mileage and just sat for a long time...what do you guys think?

Reply #9November 17, 2022, 12:36:59 am

fatmobile

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Re: 1.6TD manual boost controller
« Reply #9 on: November 17, 2022, 12:36:59 am »
 Is this a turbo that came from a VW TD?
I've never used a T3 but heard they don't provide much boost on a diesel.
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #10November 17, 2022, 05:05:23 pm

oblique

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Re: 1.6TD manual boost controller
« Reply #10 on: November 17, 2022, 05:05:23 pm »
Yes, T3's came factory on the earlier 1.6TD's I believe. It is a drop-in for mk1 and 2, mounts up identical to K24. The main advantage is that the wastegate is more reliable...as we know the K24 gets sticky.



Also, the some of the turbos that came on ecodiesels were the Garrett T2's which I believe are the counterpart to the K14's. Quite rare though.
« Last Edit: November 18, 2022, 08:41:36 am by oblique »

Reply #11January 28, 2023, 01:09:02 pm

GypsyR

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Re: 1.6TD manual boost controller
« Reply #11 on: January 28, 2023, 01:09:02 pm »
Little late but the above R3 is exactly what's on mine. Originally from a Quantum. I worried about upping the boost until I tweaked me fueling about right. Then I found I could make the clutch slip on freeway onramps at the top of third gear. So more boost would avail me nothing and I had to dial my fueling back a bit. Not really wanting to try and source a 16V Scirocco larger clutch setup as my clutch was new at the time I've settled on what I have. My boost gauge had never shown me over 6psi but I've never been sure about its accuracy.

Reply #12February 16, 2023, 03:05:25 pm

RabbitJockey

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Re: 1.6TD manual boost controller
« Reply #12 on: February 16, 2023, 03:05:25 pm »
I know I am really late on this but there is some questionable info here.

there were and are lots of people who run 30psi on stock engines, I dont recommend it as i've had bad experience with it and melted 2 engines. both of my engines could have been tuned better and i either did not monitor egts or left they go above recommended levels. Either way 30 psi on a stock engine with a cranked stock pump is not the same as 30 psi on a stock engine with a giles pump which is actually delivering proper fueling at high rpms where heat builds up rapidly.

stock wastegate pressure is usually about 8psi, to go higher than that you will need a mbc or to disable the wastegate which requires different methods depending on which turbo you have. i think its best to keep the waste gate working and use a mbc.

to go over 12psi you will need to disable the bov. i'm not sure why vw ever installed the bov as over spinning the turbo by it opening seems worse than an engine receiving ~15psi of boost. i guess vw agrees with that statement because they ditched the bov on all their diesels after the 1.6td, including the ecodiesel.


about fueling every engine is probably a little different but on my old 1.6td i could only get about 15psi from the k24 with stock fueling. above that you will need more fuel to drive the turbine enough to make the desired boost pressure. primarily you will want to control boost with the mbc, and then adjust fueling for safe exhaust temps. if you cant reach desired boost levels try some more fuel but i would do that AFTER adjust the mbc.
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