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Engine Specific Info and Questions => IDI Engine => Topic started by: Alleslowbuged on January 31, 2010, 05:59:21 pm

Title: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on January 31, 2010, 05:59:21 pm
Hi,

i have owned a VW Golf II GTD with 1.9AAZ engine for a couple of weeks.
It was in good shape and has a small K14 charger, which cause very quick spool
and brings up to 1,5 bar with sticking wastegate. After the first pump adjustments
i notice the new cluth is not able to transfer the quick spool torque.

Here some pictures, how it looks when i bought it:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/P1010013.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/P1010014.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/P1010015.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/p1010007.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/P1010008.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/P1010011.jpg)

Even with the overloaded clutch i have run some g-tech turns and one 1/4 mile race, best result is 16,5s for 1/4 mile.
Here is a G-tech result, compared with my old 1.6 TD (red line)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/2009_Golf-2_GTD_2009.jpg)

Unfortunately a pice of the head brokes, during i wand change the two spring nozzle against new one spring DN0DS297er nozzles.
After i few minutes of disbelieving looking, i acceped that i have to pull the head, so actually the head is dismount and also the gear is out of the car. I will swap to 02a tranny (CTN) and 228er clutch, which i allready have. Because i did not know how to fix the head, i have bought an other head, which will be rough ported at the exhaust ports.

Here are some pics from the broken head, it is an AMC head and has max. seen 20tkm, no cracs no wear.
(the green stuff is liquid metall glew, hopeless trial)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC01928.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC01925.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC01927.jpg)

In the last two days i have disassemble the head, because i will further use all the internals (8mm valves). I have also start to disassemble the turbo, because the wastegate was sticking and i wand to increase the flow through the poor stock downpipe. The turbo has an exhaust of d=54,5mm, the downpipe has an entry diameter of 53,5mm and an exhaust diameter of only 44,5 mm.

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC01980.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC01981.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC01983.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC01986.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC01932.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC01955.jpg)
02a shiftbox
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC01957.jpg)
02a shift cables
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC01956.jpg)
some head internals:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC01968.jpg)
Her some pictures, were the very small exhaust port can be seen:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/kanle.jpg)

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine
Post by: Alleslowbuged on January 31, 2010, 06:13:05 pm
Hi agian,

even as i was happy with the quick spool K14 charger, i am unsure if i should use it further or swap to another charger.

I have follow turbo charger, which i could use:
a) GT15 (VTG) from a AFN TDI engine
b) stock charger from AHU TDI (non VNT)
c) stock AAZ charger (non VNT)
d) K14, was installed
e) K24, from my old MK1 TD
f) Switzer S1B (there i have to use a external wastegate)
g) GT2052V (VTG) from 2,5 TDI engine

I would apreciate to read your suggestions, the car is a daily driver, i shedule to increase the boost up to 30psi (only for short time)
For normal driving max. boost should be between  18psi and 22psi.

Best Regards
Clemens
Title: Re: Golf II GTD with 1.9 AAZ engine
Post by: rallydiesel on January 31, 2010, 06:31:17 pm
Nice car. I would like to build something similar. I would try out the vnt20. However, for a daily driver the k14 might be easier and more torquey.
Title: Re: Golf II GTD with 1.9 AAZ engine
Post by: Alleslowbuged on February 03, 2010, 06:33:36 pm
Hello,

thanks for your suggestion, i have the thinked in the same direction.
But yesterday i have read another post here, which compared a K14 with a K24 charger
on a 1.9er IDI engine. The result for me is, that the K14 will be very good for low end
torque and also captable for enough boost, but will cause high oil temp and also high
intake and exhaust gas temerature. So as high temperature is the real IDI engine killer,
i think i will use the gt2052 (complicate governor issue) or my good old tough T3 from
the 1.6 mk1.


Best regards
Clemens

Title: Re: Golf II GTD with 1.9 AAZ engine
Post by: Smokey Eddy on February 03, 2010, 07:52:47 pm
Garrett T3! :D
If you are skilled you can TIG weld that injector boss back into place. On my old head someone had successfully done that.
Title: Re: Golf II GTD with 1.9 AAZ engine
Post by: Rabbit on Roids on February 03, 2010, 08:00:13 pm
Garrett T3! :D
If you are skilled you can TIG weld that injector boss back into place. On my old head someone had successfully done that.

but he already got contaminants on the aluminum. and aluminum is super porous. and needs to be very clean to do a good weld on it. oil and anything thats going to burn away when you are welding is bad. if he hadnt tried to glue it back on, he MAY have been able to save it, depending on how dirty the engine has been through out its life. if it was one of those cars that has a ahlf inch of black goo caked to the front of the engine, i wouldnt even attempt to weld it, it wont hold long term.
Title: Re: Golf II GTD with 1.9 AAZ engine
Post by: NintendoKD on February 04, 2010, 01:11:06 am
You could try baking the block after a good acid bath, bake at 450F for approx 30 min, then let it cool, then bake again @ 300 for an hour or so, to evaporate any and all oils goops and glues.   Then you could try welding it.  If you do all of this yourself, it may be woth it.

Good luck, Cheers,

Kevin
Title: Re: Golf II GTD with 1.9 AAZ engine
Post by: Alleslowbuged on March 18, 2010, 06:44:09 am
Hi,

after a couple of weeks, i get it back to the streets on last saturday (night).
First as information, i have buy a new head and a friend has extend the tiny exhaust ports. After i reassemble
the head i found out, that i should have uses the little protection cover during mounting of the valve stem seals.

Anyhow, i bought new seals and wand to disassemble the head again, but could not dismount the old valve steam
seals, because the valve guide was however why to deep in the head. So i have to find a motor shop and ask them
to drove back the valve stem guides. After doing this i could reassemble the head finally.

I have worked on the wastegate valve, so that it is moving again, as it should be and stay with the K14 charger.
Now my electronic boost governor is also working fine.

The copuling swap to the d=228mm was also a bit annoying, because i get no M7 screws with the coulpling an need
one week to get them. The stock very heavy 02a flywheel is max lighten and needs a lot of balancing after that, now
it is a bit less heavy than the stock 020 flywheel.

The Tranny swap was quite easy, but i need a lot of time to change the shaft drives and swap the inner joint from 90mm to 100mm.

I have also noble metal lighten the catalyser and install a d=63mm exhaust all the way down after the catalyser. I has sheduled to also change the downpipe, but find now time for it.

On my first way home from the garage, i lost one of the exhaust clamps and the exhaust lay on the street.
After i fixed that, one of the new installed injectors stop working (live only 25km) and on the way to my garage a part of the shifting
cables broke, so i only have the third gear and a hoorible runnig engine.

Actualy i have change the broken injector with a old one, has redesigned the shaft cable hookup and car is running.
I also get yesterday the right tacho cable (Golf MK2 with 1.3 gas engine), so that i my tachometer is working now. Speed is good and the engine pulls like hell, but i am not satisfied with the way the engine is running, i think the cause for this is the installed DI camplate.

I have bought to Iveco IDI injection pumps from the uk yesterday (one with 11m and one with 12mm head) and will use either one of the camplates from these pumps or the complete 11mm head for my installed special pump. During the time i wait for for the iveco pumps, i will put my 12mm gilles pump to have the best possible performance reference for my own pump build.

So if everything is working as i shedule, i will make a dynorun tomorrow and also present some G-Tech results.
Here some more pics:

"lightwheel"
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02031.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02032.jpg)

ported head:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/P1010002-2.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/P1010003-2.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/p1010006-2.jpg)

self build cuppling cable holder up:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02020.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02022.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02025.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02027.jpg)

broken and then redesigned shaft cable hookup:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02042.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02043.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02044.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02045.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02046.jpg)

new exhaust:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Auspuff-1.jpg)

worse video:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/th_MOV02047.jpg) (http://s702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/?action=view&current=MOV02047.flv)


Best Regards   
 

   
Title: Re: Golf II GTD with 1.9 AAZ engine
Post by: Alleslowbuged on March 23, 2010, 03:58:01 pm
Dear all,

as mentioned i was on the dyno on the last Friday.
Before i have swap my own rebuild pump against a giles pump with a 12mm head.
I will use this dyno run as reference for my own pump, which will be reinstalled after
i get my new camplate(s).

What is very eye-catching is the peak power at approximate 3500rpm, which is very low.
From my prospective it is related to the K14 charger, which is to small at all for good peak
power. This is my first dynorun were something like this could be seen, ---- it is also my
first dynorun, without a working wastegate valve.

So in summary, the K14 has to leave this car.
Here are the power curves vs. speed, the run is taken in the 4. gear of the CTN (02a) tranny with 195/50 15" tires.
We have made at least to runs, one with 1,0bar and one with full possible boost (shortly 1,5bar).
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-2_GTD_1bar_Leistungsdiagramm.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-2_GTD_15bar_Leistungsdiagramm.jpg)

Here are the same results, taken in excel to plot also the torque curves:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Leistung_AAZ_Mrz_2010.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Untitled.jpg)

Also please find attached two short vids, one with exhaust smoke at 1,0 bar boost and the other were bosst rising could observed.
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/th_MOV02048.jpg) (http://s702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/?action=view&current=MOV02048.flv)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/th_MOV02049.jpg) (http://s702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/?action=view&current=MOV02049.flv)

Best Regards
Clemens
     
Title: Re: Golf II GTD with 1.9 AAZ engine
Post by: rallydiesel on March 23, 2010, 04:07:29 pm
Good thread!
Title: Re: Golf II GTD with 1.9 AAZ engine
Post by: Alleslowbuged on March 23, 2010, 05:39:44 pm
Hi,

@ Rallydiesel
thanks

I forgot to add the new G-Tech run result, which was taken on last thursday evening (before the
dyno run)

I could decrease the drag strip time to 16,2s.
(red is actual setup, black is from last fall with light modded stock pump and green is my BMW 524TD ;D )
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-2_GTD_AAZ-Giles_20100323.jpg)

This are the power and torque curve
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-2_GTD_AAZ-Giles_20100323-2.jpg)

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine
Post by: smutts on March 24, 2010, 03:28:46 pm
Looks like that AAZ was born there, looks as though I will be looking out for one to replace the poor SB that the ladyfriend drove 20 miles with no oil in it. "Whats that annoying buzzer and red light for?" DOH! AND a home for that K24 that is sitting in my cupboard! Happy Days Are Here Again! ;D

Did the chassis rail need hitting to get the serpentine belt to fit?
Title: Re: Golf II GTD with 1.9 AAZ engine
Post by: Eivind on March 28, 2010, 03:18:34 pm
Nice car! Allmost like mine, I also have a tornado red GTD with a AAZ, but I run the T3 from a 1,6td and a fmic but still with stock ip, injectors and exhaust.
Fun to see the dyno result, but I didn`t see if thos numbers was that on the crank or the wheels?
Title: Re: Golf II GTD with 1.9 AAZ engine
Post by: stewardc on March 28, 2010, 03:51:40 pm
That's one nice ride. I always thought a Mk 2 GTD AAZ would be the ideal daily driver.
Title: Re: Golf II GTD with 1.9 AAZ engine
Post by: Alleslowbuged on April 08, 2010, 07:56:12 am
Dear all,

i have change the the last old injector against a new one (remember, one of the new injectors was broke just after restart) and change the injection pump back from the giles pump, to my own modificated pump with 10mm plunger. Before i reinstalled my pump i has to make some further modifikations and change some internals, because my first try was not good in some details.

Anyhow, the car is much stronger now as before (i did not know what percentage is related to the other pump and the new injector) either in torque as also in peak power. G-Tech gives 20kW more peak power with is plausible from the subjective drive feeling.

The dyno shop hat has no time for me, so i make a short tach vid 0-160km/h:
eigene_pumpe_tacho-april-2010.AVI (http://www.youtube.com/watch?v=0KA3SsWCBtE#)

Best Regards   
Title: Re: Golf II GTD with 1.9 AAZ engine --- vid inside
Post by: theman53 on April 08, 2010, 09:07:10 am
cool
Title: Re: Golf II GTD with 1.9 AAZ engine --- vid inside
Post by: Alleslowbuged on April 10, 2010, 07:22:49 am
Hi all,

today was second dyno time, know with my own pump. G-Tech number for peak power increasing was quit accurate.
See here the results:

first run with 1,0 bar (~15psi) -- 151hp@3600rpm / 340Nm@2520rpm (251lb-ft²@2520rpm)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-2_GTD_1bar_Leistungsdiagramm-A.jpg)


second run with 1,5 bar (~22psi) -- 165hp@3600rpm / 350Nm@2660rpm (258lb-ft²@2660rpm)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-2_GTD_15bar_Leistungsdiagramm-.jpg)

here with comparement to the first dyno run and with additionally torque curves:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-2_GTD_Drehmomentdiagramm-April.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-2_GTD_Leistungsdiagramm-April-.jpg)
Title: Re: Golf II GTD with 1.9 AAZ engine --- second dyno
Post by: Alleslowbuged on July 04, 2010, 07:10:08 pm
Hi,

as i have written in an other thread, my K14 turbo has make lot of trouble with the wastegate, so that i did not have boost for the last 6 or 7 weeks. Last weekend i have swap the K14 with a K24 turbo, but have only 9 time full boost pressure before the K25 wastegate has the same failure as the old K14 turbo. By the side the K24 turbo from a friend has also the same failure with the wastegate valve on his 1990 1.6 Jetta.

So today i change again the turbo, know to a old Garret TA03 turbo from a 1988 VW Passat. The size is nearly the same as the K24 turbo, but up to know i would say that the Garret spools earlier as the K24.

From my calculations i should have approximate 12 hp to 15 hp mor peak power and a bit more than 100 °C lower exhaust temperature, by lowering the exhaust backpressure by 1,0 bar and have the same boost pressure than with the K14 turbo. I would say that the turbine side from the TA03 and the K24 is nearly twice as big as the K14 turbine side, so using the bigger turbo should bring aprroximate 1 bar less exhaust backpressure.

Here are some pics from the three turbo, to see the differend size. What was new for me ist, that the compressor wheel from the K14 has the same size as the other to bigger turbos. Anyway i have take a look on the K14 compressor map and would say that the compressor is 100% fit for 1.6 or 1.9 TD engines, only the turbine side is really to small for tuned engine.

left is K24; middle is TA03; right is K14


(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02182.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02181.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02180.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02178.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02177.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02176.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02173.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02172.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02171.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02170.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02169.jpg)

theese picture are from last week, when we installed the K24 turbo and put my second pump build in the jetta from my friend.

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02160.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02159.jpg)

Gruß Alleslowbuged

 

Best Regards
Alleslowbuged       
Title: Re: Golf II GTD with 1.9 AAZ engine --- new Turbo
Post by: Alleslowbuged on July 09, 2010, 02:49:18 pm
Dear Folks,

i am still confused, yesterday i have disconected the wastegate from the boost pipe and max. possible boost pressure is 1,2 bar, even with massive fuel injection. Even 1,2 bar is only possible in third, fourth and fived gear, in the first gear max. boost pressure is 0,8 bar. The turbo spools normal in my eyes, which means 300 - 400 rpm later than the K14 has done. So i will check exhaust back pressure next on my search of lost power. G-tech run from yesterday show up 20 kW less power and aprroximate 60Nm less torque.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- new Turbo
Post by: Alleslowbuged on July 10, 2010, 09:03:35 pm
Dear,

today i have installed the Dr. Diesel performance cam on my aaz, and will come back later with first driving results.

Best regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- new Turbo
Post by: TDIMeister on July 11, 2010, 05:21:40 pm
Hi, schönes Auto! Bin gespannt auf die Ergebnisse mit der Nockenwelle.  Was meinst Du ist mit der Einspritzpumpe von Giles los? Dein problem mit dem Ladedruckaufbau, das geht sehr wahrscheinlich um das A/R-Verhältnis.  Der Lader kam ursprünglich aus einem Benziner, oder? Ich empfehle einen VTG-Lader, z. B. aus einem VW T4 AXG.
Title: Re: Golf II GTD with 1.9 AAZ engine --- new Turbo
Post by: Alleslowbuged on July 12, 2010, 05:51:35 pm
Dear all,

@TDIMeister
thanks for you nice words and excellent german, you are from canadian or?
All turbos are from diesel engines, i don`t know what was the problem with
the giles pump, but i have to say that i have bozght it second hand, so perhaps
it is not "original giles" or some internales was changed?

I have take a look on the next turbo swap, know i will take the next bigger step
and will install an adapter for external wastegate and use a schwitzer S2a which
i allready have. Here are some pics:


(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02201.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02198.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02200.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02199.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02194.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02195.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02196.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02197.jpg)

In regard of the performamce camshaft i can`t feel any advantage in comparement to the AAZ stock cam up
to know but did not have take out an objektive measurement like g-tech run or similiar. I has adjusted the fuel
amount to the acual turbo mid of last week and have had nearly no smoke over full speed range.

After installing the performance cam, i can again make the streets very dark, without any modifications on the
fuel amount. Also the Turbo spools later than before, after boost pressure come up (approximate 3000rpm) it feels
perhaps a bit stronger than before and in upper speed range i could not feel any difference.

I was wondering about a missing oil groove for the first cam bearing:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02189.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02188.jpg)

Here some more pics from the camshaft:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02186.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02185.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02184.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02183.jpg)

Be changing the cam, i have notice that the inlet hydros of the first and the fourth cylinder has a mark of the
cone point from the cam, so i decided to change both hydros with two from an other aaz engine.

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02190.jpg)

Best Regards
    

  
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: Alleslowbuged on July 12, 2010, 05:55:18 pm
Hi again,

i also forgot to show new pics with acual shocks, springs and rims and tires:

Pre - Work

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02090.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02092.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02094.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02097.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02101.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02102.jpg)

Result:


(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/front.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/front-2.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/heck.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/p1010004-3.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/p1010005-3.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/P1010009-3.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/P1010010-2.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/P1010012-2.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/schrg-vorne.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/schrg-vorne-2.jpg)

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: stewardc on July 12, 2010, 06:28:40 pm
FWIW, good camshaft manufacturers will always tell you to install new cam and new lifters together. Never reuse either one without a matched set.
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: TDIMeister on July 13, 2010, 05:59:47 pm
Hi Alleslowbuged, since the other car in your picture has Kennzeichen aus Bielefeld, and the seal on yours is from Nordrhein-Westfalen, I assume you're from NRW, probably not far from BI. :D ;) Can you tell us, where you are located?  I lived since 2005 in Aachen.  There I studied at RWTH.  At the beginning of this year I returned to Canada where I'm from, now I'm doing my PhD (Doktorarbeit) in Maschinenbau.

Here are some pics (http://forums.fourtitude.com/showthread.php?4315580) of my car in Germany and previously my Diesel (http://www.vwvortex.com/artman/publish/article_853.shtml) that I owned from 2000 until 2005.

BTW, I don't normally type like this in English.

Edit: P.S. - Most turbochargers for gasoline engines have turbine A/R ratios that are too high to be able to build up boost properly in a Diesel engine.  The wastegated turbos used for the VAG Diesels all have A/R ratios around 0.3x.  Most gasoline turbos start at 0.6x -- not going to spool.
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: Rabbit on Roids on July 14, 2010, 11:07:13 am
FWIW, good camshaft manufacturers will always tell you to install new cam and new lifters together. Never reuse either one without a matched set.

x2... VERY IMPORTANT to have fresh wear surfaces. the cam and lifters get wear patterns, and they sorta like being matched wear patterns.
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: Alleslowbuged on July 14, 2010, 02:51:15 pm
Hi,

i wand to build (buy) an adapter for put the S2A on the stock manifold and use a external
wastegate. The shop who has take the order did not have a drawing for the vw stock
trapezoid flange, i have make some rough measurements last time, but was not aware that
i need the dimension for manufactoring.

If someone has a sketch or a drawing i would appreciate if i could get them.

Best regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: dts67 on July 18, 2010, 11:55:16 am
Hi Alleslowbuged, nice car! Like the bmw as well(seen the gtec figures and videos!)
I was posting in your pump thread a while back but lost it? and was wondering are you still running a camplate from a direct injection pump? Or could you share any camplate info or research? All Ive learned so far is de145(11mm vag tdi auto) is the best lift and lever modification could be required to get full rpm. I'm about to upgrade my turbo this week (finally, k14 50trim, merc OM606) on peugeot xud engine and fear wont have enough fuel especailly for high rpm, I already have 11mm plunger, approx 18deg advance, grinded custom lda pin and shimmed governor.
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: NintendoKD on August 07, 2010, 12:32:41 am
yayss SEXY TIME ;D
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: Alleslowbuged on August 07, 2010, 06:00:36 pm
Hi,

after i have had a broken injection nozzle again, the car is running again and i will drive to a 1/8 mile race tomorrow.
I have also make a modification on the front, to get more air to the oil and to the intercooler.

Here a the 2010 insect eyes for the vw golf mk II:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Front1.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02244.jpg)

I have also get a few new parts for the S2A turbo swap:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02240.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02239.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02238.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02237.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02236.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02235.jpg)

Best Regards 
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: Alleslowbuged on August 08, 2010, 06:33:44 pm
Hi,

today was racing time.

I was on a 1/8 mile race and get the first place in the diesel class "up to 150 hp" with my
good old fragile vw mk II. The track was a bit wet all the time, but on the third run it was
nearly dry and i could decrease my 9,7 s from the second run to a 9,3 s in the third run.

here a pic and three videos:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02249.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/th_MOV02248.jpg) (http://s702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/?action=view&current=MOV02248.mp4)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/th_Video007.jpg) (http://s702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/?action=view&current=Video007.mp4)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/th_Video008.jpg) (http://s702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/?action=view&current=Video008.mp4)

I am really happe with that result, because i was not even sure if i could be faster than last year with my bmw. In fact i have still only 0,8 bar boost in the first and 0.9bar boost in the second gear, which means not more than 0.9 bar boost for more than 3/4 of the complete track.

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: TDIMeister on August 09, 2010, 05:12:33 pm
Nice!
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: Alleslowbuged on August 17, 2011, 05:48:12 pm
Hi folks,

one year ago, that i last post here something regarding my mkII golf.
Beside a new pump mod to 12mm plunger and IDI camplate there was no big thing to speak about,
but here is the progress:

new exhaust, i only used the last muffler (group A, street legal):
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02329.jpg)

mounted:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf2_von_hinten.jpg)

new dyno runs with actual pump:
@1,2 bar
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-2_GTD_12bar_Leistungsdiagramm-November-12mm-a.jpg)

@1,5 bar
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-2_GTD_15bar_Leistungsdiagramm-November-12mm-a.jpg)

here are power and torque curves in comparision to the old curves, the difference is 95% the turbo (old K14, actual T3)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Leistung.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Drehmoment.jpg)

here are some pics, with new vortex rear spoiler and new exhaust (winter tires with 25mm plates per side):
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/hinten-himmel.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/hinten-1.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/hinten-seite.jpg)

Than i have had a little accident, which bend the car body, but everthing could be easly fixed, here some pics:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02495.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/kaputt.jpg)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02508.jpg)

just refit (before re-bend)
 
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC02518.jpg)

This was all only the past, actual i have dismount the cylinder heat again, which will be ported again to level two.
Also the valve seats will be machined, so that the valves will be approximate 1,0 mm deeper in the head, to exposing
more space for valve lift.  Due to the machining the valve shaft will be cut be the same amount, also the valve plate
will be cut by ~0,50 mm to expose even more valve hub.

Here is a pic of the dismounted head, which shows no cracs or something else due to my mistreatdment:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00076.jpg)

Best Regards
Alleslowbuged

   


 
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: Alleslowbuged on August 18, 2011, 12:44:38 pm
Hi,

i also forget to mention, that i change the complete brake system from "GTD" to "G60", so i have now Ø280mm disks
on the front axle and Ø226mm disks on the rear axle plus 9" brake booster and 22er master brake cylinder. In fact this
means also that i need new winter tires, because minimum rim diameter is know 15".

Best Regards
Alleslowbuged

 
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: carrizog60 on August 18, 2011, 04:52:36 pm
glad to hear that the repair was easy.
why is your dyno having that loss of power at high rpm?

maybe is low boost but with k24 boosting 2 bar i hit almost max power at 4000 and then it increased only 5hp until letting off.
i had the wg blocked and the more rpm,the more boost.you should try as you have 12mm head.

speeking of 12mm head were did you sourced yours?
2 days ago i let a 11mm head go from ebay.de, and since you are from germany(i am from portugal) i would like to see if they are easier to find there...
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: Alleslowbuged on August 18, 2011, 05:31:09 pm
Hi,

i did not know why high rpm power is lower with T3 turbo and 12mm plunger (IDI camplate) than with the K14 and 10mm plunger (TDI camplate).
Could be better advance timming of the pump or just higher boost pressure with the K14 turbo, as i now know that my previous boost gauge was
fully inexact and i therefore did not know old K14 boost pressure.

On my other car (BMW 524TD; E28 from 1986) i have also build and installed a 12mm pump (with other mods too) and have now peak power of
208 hp at 3200 rpm and peak torque of 480 NM at 2950 rpm. Before (stock 10mm plunger) i have had 200 hp at 4400 rpm and 360 Nm at 3000 rpm.
Here can you see both curves, red is actual one and green ist the previous, both has same turbo.

(http://i702.photobucket.com/albums/ww24/euro-styler/524%20td/Geschwindigkeit_E28_R10_Leistung_20110726.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/524%20td/Geschwindigkeit_E28_R10_Drehmoment_20110726.jpg)

What is clearly seen is, that as better the pump work, as earlier you get the peak power. In fact for me both engines are limit in power due to
not enough air through the valves. That is also the reason ,why i dismount the head in the golf and why i will install a 260°/250° camshaft.
lift is 9,9 mm / 9,4 mm, timming is 18°/62° - 57°/13°, spread angle 112°, valve lift in TDC 0,50 mm.

I hope to expose high rpm - huge peak power due to that, because my pump is captable for that and also the turbo should be able to bring more
boost, if more fuel can be burned at high rpm. If the golf will show that i am on the right way, the BMW will follow in the winter.

Best Regards     
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: carrizog60 on August 18, 2011, 05:36:03 pm
why not to up the boost?
with a 12mm 1.5 bar from a T3 would be low for high power right?

where did you source your 11 and 12mm heads?what cost?
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: Alleslowbuged on August 18, 2011, 05:46:43 pm
@carrizog60

i forget to speak about the 12mm head. I have bought a couple of 10 mm, 11 mm and 12mm head in last years, becausei allays buy
thoose things, if they are available, because i know that there are not available, if the need them. The used 12mm head is from a paket
of two complete iveco pumps i have bought in england serveral months earlier.

I still have one 11mm and one 12mm head here, without any using at the moment. I have also one 9 mm head (modern one from PSA), which
will fit TDI camplates plug and play, for building a 9 mm monster pump as comparision to the 12mm i used actual. So in fact i did not have any
easy source for good pump components, i just buy any if it seems a reasonably deal.

I have also have a 12mm giles pump (stage 3), which a have bought here and only used for servera days. I you or anybode else is interessted to
buy please PN my.

Best Regards    
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: Alleslowbuged on August 18, 2011, 05:55:35 pm
Hi again,

i just read you post.

The 1.5 bar during the dyno was still measured with the old gauge, so i dont know real boost.
Since the dyno last autum i have always drove with no wastegate active (excluding longer trips on german Autobahn)
max. boost level is between 1,5 and 2,0 bar, depending on gear and load. But as i say, i am pretty sure that without
hardware mods on the head and on the valves, i can not countable increase peak power over the 165 hp i have had
with the K14 turbo. Funny thing without active wastegate is, that there is nearly no blake smoke with the actual setup.


Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: vanbcguy on August 19, 2011, 04:04:12 pm
I really like the turndowns on your exhaust - wish I had something like that.  I have a dual outlet muffler but it shoots straight back, ends up getting my bumper sooty sometimes... :)
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: carrizog60 on August 20, 2011, 05:02:14 am
same here,it get worse being the passat alpine white lol
looks like a train lol

what size is your outlet on the exhaust?

any news regarding pump swap?

you are going to try a S2 but why not a vnt?
with your pump and a gt25 that would be a tyre burner lol
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: Alleslowbuged on August 21, 2011, 11:08:32 am
Hi again,

i have thinked about vnt, but i am to concerned about to much low rpm torque, as i have only stock internals and wand to stay a friendly with the gearbox for a long time. I also heard a lot of people going vnt and have broken turbos with idi engines, and beside there is also the controling issue to solve.

After long time searching i found a S2a compressor and turbo map today and it seems like perfekt fit for my goals.
Here are both maps, i try to put in boost line (from squirrel calculation) and will post that later:

(i do not know which compressor type and wich exhaust ar i have)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/S2a_Compressor_Map_20110821.jpg)

Best Regard
   
Title: Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
Post by: carrizog60 on August 21, 2011, 01:57:56 pm
i had the same concerns that you have.
your problem is solved going big.
i chose a gt2052 and its not a quick spooler in the low rpm,but is faster than any wastegated turbo of its size.
for you i would go for a 22 or 25 series,no problem with low rpm torque.

for the S2 maps...sorry to say that i dont konw how to read maps...(info on a good place to go for learning will be great tho)
Title: Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
Post by: RabbitJockey on August 21, 2011, 03:39:18 pm
compressor maps i understand, turbo maps i do not, i wasn't sure whether or not they even existed.
Title: Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
Post by: Alleslowbuged on August 21, 2011, 04:29:15 pm
Hi,

as promised, please find attached both maps, now with my assumend boost lines for compressor and turbine:

I have first put all my data (data i would like to have) in the Borgwarner MatchBot and plot the resultant compressor and turbo maps
for an EFR-6255 turbo, than i uses the results and tranfer them to the S2a maps. How accurate that is, i don't how. In my mind i think
the biggest uncertainty is the volumetric efficency, which is used as input value in the MatchBot.

Next step will be to measure my S2A, to idendify the type. I am not to concernd about the compressor, as could live with both of them,
but i could imagin that my exhaust AR could be to small.

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/S2a_Compressor_Map_AAZ_20110821.jpg)

Best Regards


    
Title: Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
Post by: Alleslowbuged on August 23, 2011, 05:44:03 pm
Hi,

i did some fine tuning on the BorgWarner MatchBot and slowly get what a wonderful tool they gave us unknowing people.
Here is what i put in and what came out for my S2A (don't be astonished by the plots for the EFR-6255):

http://www.turbodriven.com///performanceturbos/matchbot/index.html#version=1.2&displacement=1.9&CID=115.938&altitude=500&baro=14.456&aat=75&turboconfig=1&compressor=62k80&pt1_rpm=1500&pt1_ve=88&pt1_boost=4.4&pt1_ie=85&pt1_filres=0.08&pt1_ipd=0.2&pt1_mbp=0.5&pt1_ce=58&pt1_te=70&pt1_egt=1550&pt1_ter=1.2&pt1_pw=3.74&pt1_bsfc=0.34&pt1_afr=15&pt1_wts=300&pt1_wd=83&pt1_wd2=74&pt1_wrsin=69033&pt2_rpm=2200&pt2_ve=88&pt2_boost=18&pt2_ie=85&pt2_filres=0.1&pt2_ipd=0.8&pt2_mbp=1&pt2_ce=58&pt2_te=73&pt2_egt=1600&pt2_ter=1.78&pt2_pw=0.19&pt2_bsfc=0.35&pt2_afr=15&pt2_wts=320&pt2_wd=83&pt2_wd2=74&pt2_wrsin=73635&pt3_rpm=3200&pt3_ve=80&pt3_boost=30&pt3_ie=85&pt3_filres=0.12&pt3_ipd=0.9&pt3_mbp=1.3&pt3_ce=58&pt3_te=72&pt3_egt=1650&pt3_ter=2.44&pt3_pw=4.55&pt3_bsfc=0.37&pt3_afr=15&pt3_wts=340&pt3_wd=83&pt3_wd2=74&pt3_wrsin=78238&pt4_rpm=4000&pt4_ve=75&pt4_boost=30&pt4_ie=85&pt4_filres=0.15&pt4_ipd=2&pt4_mbp=1.5&pt4_ce=60&pt4_te=71&pt4_egt=1650&pt4_ter=2.63&pt4_pw=10.62&pt4_bsfc=0.42&pt4_afr=15&pt4_wts=368&pt4_wd=83&pt4_wd2=74&pt4_wrsin=84681&pt5_rpm=5000&pt5_ve=70&pt5_boost=30&pt5_ie=82&pt5_filres=0.18&pt5_ipd=2.5&pt5_mbp=1.8&pt5_ce=64&pt5_te=70&pt5_egt=1650&pt5_ter=2.74&pt5_pw=16.73&pt5_bsfc=0.43&pt5_afr=16&pt5_wts=400&pt5_wd=83&pt5_wd2=74&pt5_wrsin=92044&pt6_rpm=6000&pt6_ve=65&pt6_boost=30&pt6_ie=80&pt6_filres=0.2&pt6_ipd=3&pt6_mbp=2&pt6_ce=65&pt6_te=70&pt6_egt=1650&pt6_ter=2.85&pt6_pw=19.27&pt6_bsfc=0.44&pt6_afr=18&pt6_wts=400&pt6_wd=83&pt6_wd2=74&pt6_wrsin=92044&


I have also tried to measure main dimension and came out with that results:

   Compressor Wheel:  Ø39 mm / Ø61 mm      (Inducer / Exducer)
   Compressor Casing: 0.54 a/r

   Turbine Wheel:  Øxx mm / Ø54 mm      (Inducer / Exducer)
   Turbine Casing: 1.00 a/r

I still do not know if this is a S2A-61 or S2A-69, values in MatchBot deals with S2A-61 which should result in quick spool
and full boost of 2 bar around 3000 rpm. Exhaust backpressure will follow boost but will not overcome boostpressure up
max. rpm. I would like to have a bit bigger turbine casing to surely prevents surge, wich could be a issue.

Best Regards
Alleslowbuged   


 
Title: Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
Post by: Alleslowbuged on October 04, 2011, 02:53:20 pm
Hi,

it takes me 4 full days (nearly 8 hours per day), but the engine run yesterday at around 19:00 again.

in sequence:

First i have change the original engine bearing (behind the engine) with a special built one, which use a control arm bearing from a Audi A8.
Because the inner diameter was a bit larger than the original one, i make a bush, even when the force will be tranferred due to friction and not due to the bolt.
Anyway, here are the pictures which shows both bearings, the new one should be much stiffer:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00227.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00228.jpg)


As next step, i have modified the ventilation plate, to fit with the new Spal fan:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00230.jpg)


It took me a long time to fit the flange adapter and the wastegate flanges, by the way the exhaust manifold gets a hole for EGT measurement:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00232.jpg)


Here how all together should look:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00224.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00225.jpg)

After i cleaned the engine block, i have also cleaned the piston surface and have to notice, that there was some contact between the piston and the valve with the old arrangement.

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00233.jpg)



Than i have measured the gap between the old headgasket and the pistons (1,0 mm) and also the distance between the valve and the cylinderhead (spilt surface) (IV 2,4 mm; EV 2,1 mm) to calculate the distance between the valves and the pistons in OT (TC?) (IV 3,4 mm; EV 3,1 mm). I have also measured the max. lift of the valves due to the springs or the spring caps with 11 mm, which is not really much by a valve lift of 9,9 mm.

After the cylinderhead was put in place again, it was high noon, will the turbo fit behind (under) the fire wall?

first check (after allready change the way of some cables and dismount the heat protection):

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00239.jpg)

Seems as could be done, so i bent the heat shield and mount it with two new distance spacer:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00240.jpg)

and HERE IT IS:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00241.jpg)

quite a tight fitting with the compressor housing:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00244.jpg)


The next problem to solve was the oil pipes:

Step one
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00246.jpg)

Step two
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00245.jpg)

Step three
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00247.jpg)

making the last gasket for cooling water connector:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00248.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00252.jpg)


And put it all together an start the engine:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00253.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00254.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00255.jpg)


Unfortunately i missed to make a picture from below. Up to now the only problem which must still be solved is
the downpipe with the conection for the wastegate pipe. to be honest i don't have just a idea how to start
that, but comes time, comes solutions.

Best Regards
Alleslowbuged

Title: Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
Post by: Alcaid on October 05, 2011, 07:23:10 am
How much clearance do you have between compressor housing and firewall? Engine will not stand completely still unless you changed the engine mounts to something solid...
Title: Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
Post by: Alleslowbuged on October 05, 2011, 02:48:49 pm
Hi,

the clearence is only a few mm to the heat shield and heat shield to firewall again ~ 2 mm.
It is clear that the engine will move a bit, i hope that the new "special" engine bearing will prevent to much movement, but
in fact i have to wait until the first drive, bevore i will know if it is enough clearence or not. At least i can bent the firewall
in that area a bit, but from my feeling it will be ok.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
Post by: Alcaid on October 05, 2011, 02:58:39 pm
That is not enough clearance! :o
Title: Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
Post by: Alleslowbuged on October 05, 2011, 03:03:32 pm
Hi,

did you see, that i have a special engine bearing?

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
Post by: Alcaid on October 06, 2011, 08:34:51 am
If the mount is so stiff that the engine won't move a couple of mm, I guess your car will shake apart! ;)
Title: Re: Golf II GTD with 1.9 AAZ engine --- going EVO II
Post by: Alleslowbuged on October 09, 2011, 05:06:38 pm
Hi,

it seems to be realy a bit mor "shaky" as i like.

I have start to fabricate the downpipe this weekend, actualy i am finished the vertical part and
have the downpipe face the catalysator. I will add a flexpipe and make an aditionally support in
the near of the catalysator, then i have Ø 63,5 mm straight ahaead all the way down.

What is still open to make is the wasteagte pipe.

Here some pictures:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00265.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00266.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00267.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00268.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00269.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00270.jpg)

Best Regards
Alleslowbuged
 
Title: Re: Golf II GTD with 1.9 AAZ engine --- party fog mashine
Post by: Alleslowbuged on October 16, 2011, 04:35:28 pm
Hi,

it is as it seems to be allways.

I have meke my first few km wih the new setup, and besides a bit oil leak from the drain pipe of the turbo, it seems to ok.
Engine has good start, stable idle and feels prettry good in NA mode (no boost 1000 rpm - 2000 rpm).

BUT, it smokes white like hell, especially at idle when the engine is warm. Up to now i did not have make any measurements
or checks, so could be a few things. But my assumption is that there i a leak between the cooling system and a exhaust port
in the cylinder head. As i wrote, i can the start the engine normal (cold and warm) and it rand also normal but smokes like hell.
So i assume that there is no water in the cylinder. An additionally hint is that the downpipe flange seems to be a bit wet, last
weekend after i have start the engine for a few minutes.

Anyway here are the last pics, which shows all together before the ride out:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00275.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00276.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00277.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00278.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00279.jpg)

Besides, the stiff engine bearing really transver all kind of vibration into the cabin.

Best Reagrds
Alleslowbuged
       
Title: Re: Golf II GTD with 1.9 AAZ engine --- party fog mashine
Post by: Alleslowbuged on October 20, 2011, 03:58:00 pm
Hi,

i have make a few more km with the AAZ Golf, but it still has make a lot of white smoke.
I have also notice that the adapterflange is allready cracked after long 8 km with less than
3 psi boost pressure and not more than 2800 rpm.

Afterwards i have dismount the turbo and the exhaust manifold and have notice that i really
have a collant leackage in the exhaust port of the first cylinder.

f*** O*f

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00288.jpg)

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: Alleslowbuged on October 26, 2011, 01:20:31 pm
Hi,

i have spoken with a engine rebuilder on monday, which claims to have experience with
welding cylinder heads, but also says that this is a difficult thing. I have send him pictures,
but he did not call me back up to today. I will try to find a second opinion, if someone here
knows a shop with big experience with my issue, i would really apreciate if he sends me a PM
with the contact details.

Here are the pictures:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/PICT0143.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/PICT0145.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/PICT0146.jpg)

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: ibizz on November 03, 2011, 08:39:52 pm
thats bad

too mutch porting ?

may be a new used head is more economical than a repair

i hope it all be fixed soon

Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: theman53 on November 04, 2011, 12:03:44 am
You are on the right path. That is exactly what my guy says happens when porting right, SOMETIMES. The water jacket is right there and some castings aren't all that great and you get a little bleed through. Shouldn't be to hard for an experienced guy to TIG. I wouldn't scrap it that is for sure.
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: Alleslowbuged on November 05, 2011, 09:57:39 am
Hi,

thank for your oppinion. I also realy don't wand to scrap the head, not only because the porting (i thnik the guy who make the proting, will reply the porting on a new head for almost free of charge, because this crack happend), but as i wrote the head has a special valve grinding, which makes more room for valve hub.

I still do not have a statement of a shop, who says "yes we have experience which welding cylinder heads and we can do it".

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: Toby on November 08, 2011, 03:33:00 am
I would not try to weld up the area of the water leak. It will likely just fall through when the puddle forms making a much bigger hole. All of this cam be fixed, of course, but only by heating the head to the point where it warps and seats and guides may drop out. BTDT

I would try some of the low temp (400*F) aluminum solder to seal up the leak. You can solder aluminum radiators with it. Its PFM (Pure Fargin Magic) and cheap. If you can't find it over there I could mail you some.
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: RabbitJockey on November 08, 2011, 07:45:35 am
hmm that turbo looks just about perfect, i'd like to see a more detailed compressor map with efficiency islands.  why so much work with the cam and porting then u are still using the stock intake manifold with that extreme bottle neck in the elbow.
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: Alleslowbuged on November 08, 2011, 05:39:52 pm
Hi,

you are right about the intake manifold, i have start to build a dual plenum for more than one year, but a shop has make the welding wrong and so i have
to start again on that issue. Actual i only wand to bring this setup in a running status, before i try "big" numbers i will change the intake manifold.

Best Regards
 
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: Alleslowbuged on November 09, 2011, 07:26:11 am
Hi,

i was in a engine rebuilder shop today, but the told me that they could not weld it, because it is to difficult to get to the crack with the tig torch and the welding rod.

@Tobi,

many thanks for your suggestion, i will go on and will try to solder the crack. I have just speak with a retired alu soldering specialist, who means that this could work.
He recommended to use a 400°C tinning solder (soft solder) together with flux compount for hard soldering. From my personal feeling i would say hard solder should work even better as its getting capillary on the right temperature, but there could be the problem. How to ensure temperature above 560°C but below 650°C at this position.

I have allready ordered the solder material, next is to get clear how to heat up the head all-over up to 200°C - 300°C.

If you have successull repaired a cracked cylinder head with soldering?

Best Regards
Alleslowbuged   
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: vanbcguy on November 09, 2011, 10:33:33 am
Since it's an intake port, epoxy is another option.  Some race builders in fact will go in to the water jacket on purpose, and then use epoxy to rebuild the port to the shape they want.

If you search 'epoxy head porting' on Google you'll find quite a bit of info...
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: rabbitman on November 09, 2011, 02:19:52 pm
Since it's an intake port, epoxy is another option.  Some race builders in fact will go in to the water jacket on purpose, and then use epoxy to rebuild the port to the shape they want.

If you search 'epoxy head porting' on Google you'll find quite a bit of info...

It's actually the exhaust port ;D.......and yes I'd try getting it welded before just scrapping the head.
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: Alleslowbuged on November 21, 2011, 02:07:42 pm
Hi,

i have tried to solder the crack last weekend. For soldering i have had to get temperature of min. 400°C, but even with preheating to hole cylinderhead up to 280°C and using two propan burner (each with flame temperature of 1900°C) i could not reach necessary temperature. By trying to solder i have open the crack, which is now a hole (appr. 7mm x 5mm).

I now look for a "new" AAZ cylinderhead, if any wand to sell one for a reasonable price please contact me.

Here is the crack:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/PICT0145.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/PICT0143.jpg)

Here is preheating (4,5 kW)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00300.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00303.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00301.jpg)

Here is the hole:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00304.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00307.jpg)
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: R.O.R-2.0 on November 21, 2011, 02:13:05 pm
you got it TOO HOT, and burned the material.. aluminum burns, it doesnt melt..
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: Alleslowbuged on November 21, 2011, 03:19:09 pm
Hi,

no i did not get it too hot. The crack transform into a hole due to mechanical pressure from a screwdriver not due to heat.
There was no point at no time with a temperature higher than ~420 °C

I had scheduled to solder with "hard solder" at a temperature of 560 °C, but even with the two burner there was no chance to even reach 500 °C.

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: vanbcguy on November 21, 2011, 03:28:08 pm
There are some very high temperature epoxies out there, such as this one:

http://www.cotronics.com/WEB%20SHEETS/7032%20color%20wear%20plate%20NP.pdf

Rated up to 2000°F...
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: BlueMule on November 21, 2011, 05:41:28 pm
Alles, before trashing the head please look at this product. No preheating needed, oxy/acet might work best for your application. I have heard of some head builders here in the US using it to do port relocations, of course it just might be a vicious rumor  ;D


http://www.aluminumrepair.com/gas-welding.htm

BlueMule
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: Toby on November 21, 2011, 08:56:57 pm
The solder that I was talking about has a much lower melting temp. At 560C you would have had the valve seats and guides fall out, so it is good that you did not get it that hot.

http://www.alumaloy.net/alumaloy1.htm

http://www.youtube.com/watch?v=TZ5sD9hQTyw

I use this stuff and it is PFM. Just make sure that you don't get the item to be repaired too hot before you put the solder to it. Put the solder to the work as it heats up. It will flow when it is hot enough. This stuff is great for repairing ICs and aluminum radiators.
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: Alleslowbuged on November 22, 2011, 02:56:28 am
Hi,

i think i did not wrote it very precisely, i had used a solder material with a melting temperature of aprox 380-400 °C.
Before we start i have scheduled to use the higher temp solder material, but than recognize that we will not reach
temperaures in that region. The solder i have used is normaly used without flux, but the expert from shop, where i have
get the solder from, means i would be good to use the flux material even with this solder, because i allready expected
that it will be difficult to get the necessary temperature.

Now i have the problem, that a nameable amount of the solder material is flowed into the water chanel i dont thnik i can
remove it from there, even if it is not really melded together with the head. At the end the problem was, the the hole was
so big, that the surface tension from the fluid solder material was not high enough to close the hole, specially because i
must remove the oxid layer of the head through the fluid soldermaterial.

Best Regards
Alleslowbuged

P.S.
I think i will get a "new" cylinderhead for a reasonable price at the end of the week.
 

 

 
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: MJF on November 22, 2011, 06:04:09 am
What is reasonable price? New empty heads are starting at 200€ in Germany.
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: RabbitJockey on November 22, 2011, 07:16:15 am
so how much were these opened up, just from the pictures those exhaust ports are huge, are they just gasket matched?
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: Alleslowbuged on November 22, 2011, 12:58:16 pm
Hi,

the ports realy looks big on the pictures, but they are "just" gasket matched.
Even if i will buy another cylinderhead i will make a second try with this head
to solder it up tomorrow evening.

Resonable price will mean 120,- up to 150,- € for a good original VW head (empty)
incl. shipping.

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: RabbitJockey on November 22, 2011, 05:39:16 pm
yes i know gasket matching on the exhaust ports is actually the removal of alot of material

(http://img.photobucket.com/albums/v306/Trev0rbr/DSCN0798.jpg)
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: Alleslowbuged on November 29, 2011, 04:28:57 pm

... some say it was a bit of rubbish, they say it has eaten 100 kg of solder,
... all what we know is, that it running again.

As promised i have make a second solder try last weekend, here is the result:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00324.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00323.jpg)

Today it was crunch time and i have regrind nearly all that solder out again:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00325.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00326.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00327.jpg)

After that i have reassemble the head and bold it down on the engine. I was not sure and i am still concerned
if that will work for a couple of hours, but up to know it seems to be sealed. I have restart the engine, refilled
cooling water and let it runnig on idle up to working temperature, without any manifold, so i could take a look
directly to the place where the hole was.

What i do not know is, what will happend due to the big amount of solder in the cooling channel when it comes
to hotter times than idle speed.

Instead of waiting for the cylinderhead cooling, i started to manufacture a new intake manifold, after i measure
the main inlet of the stock inelt manifold with 15 cm², while each port has 12 cm²?


(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00310.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00313.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00314.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00315.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00316.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00317.jpg)

Best Regards
Alleslowbuged 
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: theman53 on November 29, 2011, 05:49:42 pm
Beautiful. I am sure others will say otherwise, but anytime you can make scrap run it is beautiful. Like the intake too.

Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: Toby on November 29, 2011, 07:36:05 pm
Nice work. Shouldn't the slot be tapered, though? Did you make the turbo adapter, as well?
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture
Post by: Alleslowbuged on November 30, 2011, 03:36:06 am
Hi,

thanks for the nice words.

I don't think that the slot should be tapert, but it would be better if the pipe would be tapert in that area.
Pherhaps i will cut the pipe after it tis connected to the lower manifold part, but i am not sure if i shoud do
or not. I think on the other about about leting the pipe open to both sides, so that i have more options for
a later intercooler upgrade.

The turbo adapter was make by a shop special for me, but it is welded as scrap and i dont think it will be work
long time. The first attemp of the adapter was running for 8 km before it cracks on the wastegate pipe. Now they
have just rewelded the crack, but i can still see the rest of the crack from the inside, so i think it will crack again
in very short time. It is very poor if you give your money to an "expert", and than reconize he is not a expert for
his buisness at all.

I will make the next driving km (only running in the camshaft), if the port will stay sealed, without the external wastegate
and hope that the adapter will captable for taking just its own weight. Than we will see what's happen.

Best Regards





 
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture -soldered
Post by: RabbitJockey on November 30, 2011, 07:27:04 am
technically on a dual plenum manifold you would want the inlet there to be tapered, the further away from the inlet the smaller it gets so that equal velocity is the same the whole way across, much like how the schroll of a turbo housing gets smaller around the wheel.  but i think you can accomplish the same thing like you have said by pipe being tapered down in size the further u get from the inlet as well, much like the ducting in a house gets smaller the further it gets from the furnace in order to maintain air speed.
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture -soldered
Post by: Alleslowbuged on December 03, 2011, 03:04:18 pm
Hi,

33

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00330.jpg)

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture -soldered
Post by: BlueMule on December 03, 2011, 06:04:34 pm
Alles, it looks like you have done a good job on the brazing, see, I knew you could do it! If it is not porous, it will be fine!! I guess you kind of freaked when your screwdriver penetrated the water jacket, but it happens, even to the most seasoned pro. Because of void spaces and differences in casting, you could have the same head, same year, and woot there it went. That’s why there is no guarantee when modifying or moving ports. Sometimes a head can be saved sometimes no. As far as the water jacket, usually your brazing would fill part of the void and not a large part of the passage itself. So on that account, I don’t think you will have a problem with this.
I do have a concern about you head though (cylinder head that is ). Usually while repairing a head in this manner, a large, flat steel plate, maybe 30mm or more is bolted to the head to prevent or minimize warpage. So it would be a good idea to check for flatness before installing. 

As far as your turbo adapter, since you said it is showing signs of cracking again, is sounds like the steel has failed at the molecular level due to heat and the vibration is just breaking the steel apart. If this is the case the adapter may be unrepairable. There are some things to keep in mind when building this type of adapter. First, if it is going to be structural, in other words supporting the turbo with no bracket, it really should be 13mm or more thick at the walls. In fact solid machined billet or cast would be best. Also 321 Stainless with 347 stainless wire or rod for consumable, if it is going to be multi piece welded assembly. Inconel is another option, but is very pricey. I think if you use the 321 and proper consumable, with a well thought out bracket to support the turbos’ weight, this should cure your cracking of the adapter.

Now, on to the intake. I have enclosed a link, and according to two rally guys, the dimensions of the “funnel” are correct. I don’t know because I am used to going very straight, fast and a ¼ mile at a time, but I am getting used to turning. The reason for the funnel shape is to ensure equal velocity and volume across the whole “plane” of the manifold. This design also cuts down on the curves the air has to pass through and thus cuts down on turbulence, supposedly. Anyway, Audi etc use this type of manifold for high output engines. I’ve never seen dyno specs one way or another, but it makes sense to me.

http://www.jasperintegration.com/navi.html 

Hoping you are able to finish your project shortly
BlueMule

 
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack picture -soldered
Post by: Alleslowbuged on December 03, 2011, 09:01:05 pm
Hi BlueMule,

thanks for your thoughts, the last picture shows my little garage, with golf is missing, whichs means that everything is reinstalled and i have drove the first 33 km today.
Up to knaow there is now leakage and no extra pressure on the cooling system, but the engine has only seen max. 3500 rpm and max 0.6 bar boost pressure.

Regarding the intake manifold, i have carried some cfd simulation and came to the conclusion, that my first idea will not work properly. I had scheduled to use a Ø50 mm pipe as primary pipe, but this will be way to small. At my power goals the velocity in the pipe would so high, that the stream will not make a 90° turn in the funnel, so the 4. cylinder would be hardly handicapped. By the way i have also done a short simulation with the stock intake wich shows up that the two intakes in the middle would take 70% of the flow, if there would be a equal pressure level on each port.

By increasing the pipe diameter to Ø60mm it looks way better, but i am not satisfied and will do some more research on that issue.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on December 04, 2011, 04:33:35 pm
Hi,

i have reached 189 km with no problems today and have tried to make some power in the last 30 km.
To be honest, i can not say much aboud how it feels, because the vibration and noise level is so high,
due to stiff engine bearing, that i could not really sort my subjective feelings.

The turbo comes later than expected after my calculation with the machbot, boost starts up at a bit
over 2000 rpm, but ~ 30psi are not below 3500 rpm. To spool up it really takes time, so that spectacular
torque feeling is bit missing, but therefore it feels a bit more like an na engine. I was only two time upwards
4000 rpm, but i think that i can say that it feels much more freely to rev in that region as before.

From what i have seen today, i think i have an S2A-69 with A/R = 1,1 intead a S2A-61 with A/R = 1, in regard
to the matchbot calculations, i schould be able to help spooling a bit with more fuel. All values above a with
nearly no smoke at all.

Next step wil be to change the engine bearing.

Best Regards
Alleslowbuged

 
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alcaid on December 04, 2011, 04:58:43 pm
Late spooling might be because of a badly matched, is there smaller A/R exhaust housings you could use on that turbo?
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on December 04, 2011, 05:46:01 pm
Hi,

yes could be, i have bought the turbo as "black box" on ebay, so it is not special selected.
Due to the technical data sheet, there should be A/R ratios between 0.5 and 1.0, regarding
my own measurements, my turbine housing is 1.05, but this is not listed.

As i wrote, i have made some new calculation based on a A/R ratio of 1.0 with the matchbot
calculator, whichs shows that even this turbo should be captable to spool early with more fuel.
We will see, i really like the compressor map, so pherpaps i should really try to get a smaler
exhaust casing.

Best Regards



 
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on December 04, 2011, 06:35:50 pm
Hi,

as i have wrote before, i have done some cfd simulations, all with 30 psi boost and flow for @ 200 hp:

stock,
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Stock_Inlet_Manifold_0-2kg-s_R00_20111201.jpg)

as scheduled, not much better
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Special_Inlet_Manifold_0-2kg-s_R00_20111201.jpg)

a bit better with Ø65 mm pipe instead Ø50 mm pipe
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Special_Inlet_Manifold_0-2kg-s_R01_20111201.jpg)

here with extra bend, so that the flow come from the upside:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Special_Inlet_Manifold_0-2kg-s_R04_20111204.jpg)

best version seems to be, with flow comes from the front (horizontal)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Special_Inlet_Manifold_0-2kg-s_R02_20111204.jpg)

I will do a bit more rework on something like that.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: BlueMule on December 04, 2011, 09:57:34 pm
Pssst, Alles, don't tell anyone, but your calculations/simulations should be done one runner at a time. Remember you only have one intake valve open at a time, so the flow does not move through all of the runners at the same time. In fact with a turbo, the intake can act as a kind of reservoir of air. One intake valve opens, allows air to flow in one cylinder, then closes, pressure then builds up in the intake until the next cylinders intake cycle. That is why the stock intake works as well as it does, even though it physically looks like it should not. Now if all of the intake valves were open at the same time, then there is no doubt that the center 2 cylinders would flow the greater percentage of air, but since it is one valve/cylinder at a time, the flow is more even than you might think. Turbulence is pretty bad, but think of this, if the 2 center cylinders took 80% of the air, how would the two outer cylinders fire. Again, the duel plenum is for, 1. reduction of turbulence and 2nd better distribution. At least that what the Rally guys have told me.

BlauMaulesel
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on December 05, 2011, 02:54:34 am
Hi BlauMaulesel,

you are right, i was a bit lazy bit writing, because i wrote it two time, here in english and in a german Forum in german. As you have correctly identified the cfd's are based on a fixed mass flow at the inlet and a constant (equal for all ports) static pressure at the outlet. I was aware of that flaw, but mainly wand to see the "natural" flow quality of the intake variants and have had no idea how to make a consistence simulation, without time transient calculation. I assume that a intake, which shows up equal flow with less turbulence in this kind of simulation, it will also give a good flow at engine conditions. 

My main reason to swap the stock intake is to equalize the flow (pressure losses) for each cylinder, for sure i also like less turbulence. The stock intake ports, both in the head and also in the lower part of the manifold, seems to be high flow captable, but i do not like the small 90° bend in combination with the even smaller opening on the top. I think it is fully ok, for power up to ~150 Ps but with higher boost and higher flows, i have concerns that the flow will become to unequal between the the middle and the outher cylinder, which will cause badly temperature profiles in the engine and extra load for the crankshaft.

Do you know how "experts" build up cfd simulations for intake manifolds? Do the ask for max. mass flow on each port separate?

Best Regards
Alleslowbuged   
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Mark(The Miser)UK on December 05, 2011, 10:04:56 am
Hi BlauMaulesel,

and have had no idea how to make a consistence simulation, without time transient calculation. Best Regards
Alleslowbuged   
What if you repeated the simulation 4 times, each one with only one port open?Then you can compare, and even superimpose to some extent revealing dead spots and contraflows.

At first glance, there seems to be too many zero movement regions. They look more naturally like maelstroms, but that's  the  Poe in me ;D
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on December 05, 2011, 02:43:12 pm
Hi,

spooling seems not as bad as i thought yesterday, perhaps the turbo need a few revs for " wake up" or i was to confused yesterday.
Today i have notice spooling started a bit below 2000 rpm, results in 0.2 bar (3 psi) boost at 2000 rpm in third gear and 1/3 throttle.

@ Mark
agree, i will do the four simlulations later, after i find my prefered intake variant.


Best Regards
Alleslowbuged      
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: rallydiesel on December 05, 2011, 09:39:17 pm
I'm surprised at how shallow that water passage is. Makes me hesitant to even gasket match ports. Maybe I'll just stick to just shaping the seat areas.
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: RabbitJockey on December 06, 2011, 07:38:05 am
I'm surprised at how shallow that water passage is. Makes me hesitant to even gasket match ports. Maybe I'll just stick to just shaping the seat areas.

yeah it scares me too, but atleast now i'd know how to fix it haha.  the most to gain is in the valve seat area anyway tho.

i'm surprised with such a big exhaust housing how well that turbo seems to be spooling for you.  it would be interesting to see how it does with more fuel.  as i'm sure you know every thing is a trade off, and you're not going to make crazy torque at 2k if you want to actually make big power unless you have a compound setup.  if you can maintain an efficient 30psi with proper fueling over 5k you're going to move a lot of air and make some very serious power.   :o :o awesome build
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: carrizog60 on December 07, 2011, 08:10:34 am
alles,can you make that calculations for a 1.9d intake with flow coming from the driver side?
i have one of those(looks like a gasser one),i heard that they were good,why didnt you tryed one of those?
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on December 07, 2011, 02:54:40 pm
Hi,

i have one of these and have had scheduled to use it on my rabbit project, but this was cancelled because of the D-port-shape of the na intake.
I have not found a pipe -  td-intake arangement, which convinced me really, so i allready have considered to make a simulation with the na intake.
Problem is, first that i am not sure were i have it and second that i do not remember if that the na intake will make collision with the turbo.

Yesterday i have ordered a new stock engine bearing and a additional PU inlet:
http://www.clausvonessen.de/pi22/pd49.html

I have also odered a few Ø80x2 alu pipes and a few Ø120x5x500 alu flat sheets to make the tapered intake pipe from (either for td or na intake part).

This is what seems to be best, but is to much for for manufacturing (for me)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Special_Inlet_Manifold_0-2kg-s_R08_20111204-3D.jpg)

This is what i end up with:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Special_Inlet_Manifold_0-2kg-s_R12-2_20111205-3d.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Special_Inlet_Manifold_0-2kg-s_R12-2_20111205.jpg)

But as i wrote, if the na intake will fit i will take it.

Best Regards  
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on December 08, 2011, 03:58:04 pm
Hi,

here i am again, with now nearly 300 km  on the speedo since the (second) restart.
I have driven daily to work and back and today i have looked a bid more detailed on
the bosst gauge.

Here is what i have seen (you have to expect a working wastegate):
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Ladedruckverlauf_S2a_AAZ_20111208.jpg)

after that i have again trimed the matchbot calculation and print it again in the S2a compressor map:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/S2a_Compressor_Map_R01_20111208.jpg)

I think without a wastegate i have a surge problem between 4200 rpm and 4600 rpm, assumed boost pressure will be ~3 bar (45 psi), which
would suit with the s2a compressor plot. When i go for it actual, the power increase very rapidly from 3300 rpm to 4200 rpm, then the power
increasing stops (nearly decreasing) until ~4600 rpm, than it goes forward again.

The engine bearing comes today and tomorrow i will visit the garage of a friend, were i will install it. I will find enough time i will also install the
wastegate and if everything goes on well, pherhaps i can go on a dyno on saturday. :P

Best Regards

P.S. here is the link to the updated Matchbot calculation:
http://www.turbodriven.com///performanceturbos/matchbot/index.html#version=1.2&displacement=1.9&CID=115.938&altitude=500&baro=14.456&aat=75&turboconfig=1&compressor=62k80&pt1_rpm=1500&pt1_ve=85&pt1_boost=2&pt1_ie=95&pt1_filres=0.08&pt1_ipd=0.2&pt1_mbp=0.5&pt1_ce=58&pt1_te=75&pt1_egt=900&pt1_ter=1.14&pt1_pw=5.41&pt1_bsfc=0.36&pt1_afr=16&pt1_wts=300&pt1_wd=83&pt1_wd2=74&pt1_wrsin=69033&pt2_rpm=2000&pt2_ve=92&pt2_boost=3.5&pt2_ie=92&pt2_filres=0.1&pt2_ipd=0.2&pt2_mbp=1&pt2_ce=62&pt2_te=73&pt2_egt=1100&pt2_ter=1.19&pt2_pw=2.14&pt2_bsfc=0.36&pt2_afr=16&pt2_wts=320&pt2_wd=83&pt2_wd2=74&pt2_wrsin=73635&pt3_rpm=2500&pt3_ve=92&pt3_boost=7&pt3_ie=92&pt3_filres=0.12&pt3_ipd=0.4&pt3_mbp=1.3&pt3_ce=65&pt3_te=72&pt3_egt=1400&pt3_ter=1.3&pt3_pw=0.78&pt3_bsfc=0.36&pt3_afr=16&pt3_wts=340&pt3_wd=83&pt3_wd2=74&pt3_wrsin=78238&pt4_rpm=3000&pt4_ve=92&pt4_boost=15&pt4_ie=90&pt4_filres=0.15&pt4_ipd=0.5&pt4_mbp=1.5&pt4_ce=69&pt4_te=71&pt4_egt=1600&pt4_ter=1.53&pt4_pw=0.47&pt4_bsfc=0.36&pt4_afr=16&pt4_wts=368&pt4_wd=83&pt4_wd2=74&pt4_wrsin=84681&pt5_rpm=3300&pt5_ve=90&pt5_boost=30&pt5_ie=88&pt5_filres=0.18&pt5_ipd=0.7&pt5_mbp=1.8&pt5_ce=65&pt5_te=70&pt5_egt=1800&pt5_ter=2.06&pt5_pw=0.89&pt5_bsfc=0.38&pt5_afr=16&pt5_wts=400&pt5_wd=83&pt5_wd2=74&pt5_wrsin=92044&pt6_rpm=5500&pt6_ve=88&pt6_boost=30&pt6_ie=85&pt6_filres=0.2&pt6_ipd=1&pt6_mbp=2&pt6_ce=62&pt6_te=70&pt6_egt=1800&pt6_ter=2.62&pt6_pw=18.27&pt6_bsfc=0.38&pt6_afr=18&pt6_wts=400&pt6_wd=83&pt6_wd2=74&pt6_wrsin=92044&
     
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: RabbitJockey on December 09, 2011, 07:24:10 am
Hi,

here i am again, with now nearly 300 km  on the speedo since the (second) restart.
I have driven daily to work and back and today i have looked a bid more detailed on
the bosst gauge.

I think without a wastegate i have a surge problem between 4200 rpm and 4600 rpm, assumed boost pressure will be ~3 bar (45 psi), which
would suit with the s2a compressor plot. When i go for it actual, the power increase very rapidly from 3300 rpm to 4200 rpm, then the power
increasing stops (nearly decreasing) until ~4600 rpm, than it goes forward again.

The engine bearing comes today and tomorrow i will visit the garage of a friend, were i will install it. I will find enough time i will also install the
wastegate and if everything goes on well, pherhaps i can go on a dyno on saturday. :P

Best Regards
     

so your boost vs rpm graph is based on what you have seen while driving?  Also i must ask, when you say 3 bar and 45 psi, you mean absolute pressure, correct?  as in 2 bar of boost and 30psi like your first graph shows?  also maybe with your new intake the surge problem could be solved, especially since it is occuring at only a few hundred rpms.
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on December 09, 2011, 04:27:40 pm
Hi Trev0rbr,

no i mean 3 barg or 4 bara, the pressure was that high because i was driving without wastegate. My pressure gauge has only a display range from -1,0 bar to +2,0 bar, so i did not really know what was the actual pressure.

As promised i wand to drive to my friend today, but on the way to my garage (to pick up some tools) i have had a leakage on the cooling system, at the outlet from the thermostat casing. It seems as i have not put in the splint pin correctly in place, so the o-ring connector could open freelance. So my cylinderhead has had his first serious thermic topic to go on with. As i reconize that something is not as it should be, the heating fault directly, which means there was no water left. But because i was nearly on my garage i could roll to it.

During waiting for cool down of the engine, i change the engine bearing to a stock one with a pu inlet. In fact it is a bit better than my motorsport bearing, but when the engine pulls hard, it vibrates also highly.

I also installed the wastegate and fabricated a temporary wastegate pipe, which end up parallel to the downpipe under the car. I also bring my boost controller in operation, so that i now can run with 2,0 bar boost pressure constantly.

Before i come home (a few minutes ago) i was on the autobahn and make some "full pulls" in third, fourth and fifth gear. What i can say is, that the turbo has no problem to keep the boost pressure at 2,0 bar (30 psi) over the full speed range up to the red line (~5500 rpm).

Whats about power?
In fact i dont know, yes there is power but it feels not as spectacular as want. I would suspect ~150 hp from 3500 rpm to 4500 rpm, but ww will see.
I do not know deatiled pump timing, as did not check it after reinstall the cylinderhead (the pump was not loose since last timing check) and i also did not have checked internal pump pressure. I hope to got both solved tomorrow.

Best Regards 

 
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: carrizog60 on December 10, 2011, 04:52:40 am
whats the problem with the D shaped ports on the intake?
fitting would be a pain but it would be less fabrication if it flowed good.

glad to see things moving,hope you can get your power goals :)
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on December 10, 2011, 09:57:58 am
Hi,

i meant that the na intake is not capable for my golf mk1 project (http://www.vwdiesel.net/forum/index.php?topic=12547.30), because i use there a portet mechanical head with O schape ports and i will make a manifold with a shorted 2.4 na intake (6 cylinder engine) for that engine. So in fact the 1.9 na intake would be fine for the aaz, if it suit with the turbo.

Best Regards

P.S. I wand to make a dyno run this morning, but the don't have time for me. :'(
   
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: carrizog60 on December 11, 2011, 04:29:37 am
well,best to not having time than not having money  ;D

will be here to see your dyno 8)
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on December 11, 2011, 10:46:36 am
Hi,

status update:

There are good news and there are bad news, good is that the cylinder head really seems to work under all conditions without any issues.
Bad is the the f...cking adapter is broke again today. I had 500 km gone yesterday (i achieve 30 mpg) in the evening, and have visit a friend,
so iwas on the autobahn again, but did no further full load runs. Today on the way back, the complete wastegate brokes out @ 140 km/h and
0,5 bar, so without many stress.

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00338.jpg)

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: RabbitJockey on December 11, 2011, 12:03:55 pm
Are you going to switch to the eBay 8v manifold
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: carrizog60 on December 11, 2011, 01:24:51 pm
is that made of tuna cans? ???
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on December 11, 2011, 01:52:25 pm
Hi,

@Trev0rbr
I think not, i have one of these manifolds (also for my mk1 project), but it has a T3 flange and no wastegate conection, so i would need an adapter as well.

@carrizog60
yes they take it strait from the supermarket, for 1,50$ extra you can buy the adapter also full with tuna as an option.

I have bought one of these T3-Wasetagte-T3 cast flanges, soi have to develop a solution to make it fit with stock manifold and T25 Turbofalnge.
Perhaps i can weld both end of the broken adapter together with the new one, or just make some new threads in in.

http://www.ebay.de/itm/Turbo-Adapter-Flange-Garrett-T3-to-T3-with-Wastegate-/120826221098?_trksid=p5197.m7&_trkparms=algo%3DLVI%26itu%3DUCI%26otn%3D5%26po%3DLVI%26ps%3D63%26clkid%3D4820854604225012358

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: RabbitJockey on December 11, 2011, 03:46:48 pm
There are two styles one has a wastegate. But like u said if the schwitzer is a t25 flange then u still need an adapter
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: keaton on December 11, 2011, 04:53:13 pm
Hi,

as i have wrote before, i have done some cfd simulations, all with 30 psi boost and flow for @ 200 hp:

stock,
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Stock_Inlet_Manifold_0-2kg-s_R00_20111201.jpg)

as scheduled, not much better
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Special_Inlet_Manifold_0-2kg-s_R00_20111201.jpg)

a bit better with Ø65 mm pipe instead Ø50 mm pipe
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Special_Inlet_Manifold_0-2kg-s_R01_20111201.jpg)

here with extra bend, so that the flow come from the upside:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Special_Inlet_Manifold_0-2kg-s_R04_20111204.jpg)

best version seems to be, with flow comes from the front (horizontal)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Special_Inlet_Manifold_0-2kg-s_R02_20111204.jpg)

I will do a bit more rework on something like that.

Best Regards
Alleslowbuged

What program are you using?

here is what i came up with
(http://i34.photobucket.com/albums/d101/keatonstanley/junk/1.jpg)
(http://i34.photobucket.com/albums/d101/keatonstanley/junk/4.jpg)
(http://i34.photobucket.com/albums/d101/keatonstanley/junk/5.jpg)
(http://i34.photobucket.com/albums/d101/keatonstanley/junk/6.jpg)
(http://i34.photobucket.com/albums/d101/keatonstanley/junk/7.jpg)
(http://i34.photobucket.com/albums/d101/keatonstanley/junk/8.jpg)
(http://i34.photobucket.com/albums/d101/keatonstanley/junk/2-1.jpg)
(http://i34.photobucket.com/albums/d101/keatonstanley/junk/3-1.jpg)
(http://i34.photobucket.com/albums/d101/keatonstanley/junk/NF_side.jpg)
(http://i34.photobucket.com/albums/d101/keatonstanley/junk/NF_top.jpg)

notice the fins above here is what it looks like with out
(http://i34.photobucket.com/albums/d101/keatonstanley/junk/top.jpg)
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: BlueMule on December 11, 2011, 08:41:05 pm
Alles, huge props for your progress. Nice to see the "old school" spirit of learning and doing it yourself is alive and well.

WOW, what a huuuuge breakdown on your turbo adapter. Before you start welding on anything you need to find out what the adapter that you bought is made of. You really don't want that thing to fall apart and your turbo ends up dangling like a participle from the oil feed line  :o

I still think your best bet is to buy the right material and then have someone weld it up for you. Repeat after me "321 stainless 10-13 mm wall thickness with 347 consumable" keep repeating this and all of your adapter fears will go away  ;D

As far as CFD calcs, the first consideration is how much total air (Mass) do we need to make X horsie power, if fueled properly. Then divide by cyls. At this point all cyls must flow equally in Mass and velocity. What makes a huge difference is whether or not laminar flow can be established in the runners. For this to occur the runners should be as straight as possible and not polished, a finish of 160-180 grit is preferred. 90 Degree angles are a no no. Also remember that no matter how big you make the ports, the biggest restriction in the intake are the intake valves, it makes no sense to hog out the ports if your intake valves are only X mm. These IDI heads are really not that bad in the intake department. The exhaust, however leave a huge amount to be desired.

SO keep on keepin on Brochacho

BlauMaulesel

Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on December 12, 2011, 03:18:17 am
Hi,

@Trev0rbr
could you send me link, i have searched for a wastegate version yesterday, before i bought this cast adapter, but only found wastegate version for 16V heads.

@keaton,
Nice work, i seems that you allready tuned all the small details to come up with a nice flow field. I have used SolidWorks Simulation 2011 and as i wrote before end up with the same conclusion, that the slot should be 90° to the runners. The fins are fine and looks instandly right, but are to hard to fabricate for me. I have looked for my na intake yesterday and found it at home, but i do not think it could be used with stock exhaust manifold (also with the adapter), because it nearly goes straight horizontal out of the cylinderhead, so could only be used if the turbo goes down. When did you make your calculations, i would estimate it was a lot to do, to bring it to this refined level.

@Bluemule
Thanks again for this nice words, it keeps me motivated to know that my work is a bit interessting for the people here and perhaps my faults could prevent other from having the same issues.

Regarding the adapter, i would say that the think i have bought is fully bull*** and is make from people without knowledge. I have talked to the shop owner after the first breakdown and found out, that he has exactly no knowledge about welding and temperature stress and so on, the just gave to a eastern europe country and ask for weld it together, they dont have WSP or somethink like that. In fact that meant for me, that i have lost my money and could not hope that they will find a solution.

I have seen a T3/T25 Wastegate adapter on USA ebay, the same welding style as my, but the wastegate flange is shorter, so the that the small wastegate flange is weldet on both turbo flanges on his ends. This should make the hole think a lot more rigid, because there is than no more stress concentration on the T-union weld. It also allows head flow from the heated turboflanges in the wastegate flange, even when the wastegate is closed, this should also lower the thermal stress. The cast apapter also has this connection between the wasetgate and turbo flanges.

I hope that i could find out both materials and that the cast adapter is made from cast steel, otherwise it could be welded (from me). I am not familiar with the asme code for steel, do you know the DIN or ISO code for "321". If i were the builder at all, i would make it either from 16Mo3 or 13CrMo4 and not from "real" stainless steel (gamma phase iron), to prevent whose high thermal expansion rate (~18 * 10^-6 instead of 12 * 10^-6).

Thank for your reply to the cfd also, in fact i startet your way and came up with 0,2 kg/s for 200 hp at 3,0 bara and ~100°C. I did not have make a lot of math before i ask for porting the head, but know i fully agree, that there is absolutely no necessary to make something on the stock intake ports (perhaps just match the gasket on the split plane. The stock 1,9 td ports a aproximate 20% smaler than the 1,6 ports nad they are stupidly shaped in the area of the 90° bend behind the valves. So i still assume there could be make some progress on porting them. But in fact i agree, (same was writen from trev0rbr) that the big gains are made with the valves. I hope and think that my new camshaft helps for peak power and it seems that is had no bad influence to low rpm power, as the swirl after the valve it not as importand for our idi engines. If i go for the next head experience, or perhaps even with this head again, i would also make a 30° chamfer on the valve seat ring, same as the tdi's have (i did no know before last week).

Best Regards
Alleslowbuged

         

 

 
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: carrizog60 on December 12, 2011, 08:14:58 am
Quote
The stock 1,9 td ports a aproximate 20% smaler than the 1,6 ports


i thought that 1.9 head was bigger on ports ???

Quote
i would also make a 30° chamfer on the valve seat ring

what do you mean by that?any pic?i am lost in the translation...

usually people dont mess with the camshafts,low gain they say and very few options to choose...
but what about tdi aftermarket camshaft?would they work?

also almost high hp tdi around here use diesel  radiators,can that also work on our engines?

just some ideas to help reach the most safe hp  ;)
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: theman53 on December 12, 2011, 08:19:33 am
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00338.jpg)

Looks like regular old box tubing would have held up better. You could take that off and get some or a nice piece of round pipe that you could weld and gusset it for strength. Libby used to do that stuff all the time. ARB, the guy that build the minivan did too. The hard part of that piece is the cut port and holes in it, so you at least have something to work with.
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: RabbitJockey on December 12, 2011, 11:49:09 am
i thought there was another version more similar to the non wastegated ebay manifold, but kinetic makes a wastegated version, here are a few i found, a but pricey in comparison... but u gotta pay to play i suppose.

divided/twin scroll:
http://www.ebay.com/itm/Spa-Turbo-Manifold-Volkswagen-All-Models-Water-cooled-/310324992408?_trksid=p5197.m7&_trkparms=algo%3DLVI%26itu%3DUCI%26otn%3D2%26po%3DLVI%26ps%3D63%26clkid%3D4842043956152208062

and a regular one, i believe this is either the kinetic manifold or a copy of it

http://www.ebay.com/itm/Spa-Turbo-Manifold-Volkswagen-All-Models-Water-cooled-/310324992396?_trksid=p5197.m185&_trkparms=algo%3DSIC.NPJS%26itu%3DI%252BUA%26otn%3D12%26pmod%3D310324992408%26po%3DLVI%26ps%3D63%26clkid%3D4842045357118754943



dave used one on his build

http://www.vwdiesel.net/forum/index.php?topic=11698.0
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on December 12, 2011, 02:23:04 pm
Hi,

are you sure that they have a wastegate connection? As there is only one small picture and they also did not decribe any dimensions or details, even on they homepage, i could not find out. I am also not sure, if i have enough place between manifold and firewall, to suit turbo and manifold.

I was also in the kinetic motorsport page, and like the angular flange more. In combination with a non wastegate T3/T25 adapter, which are shorter (~52 mm; ~ 2 ") this should give the most reliable solution and should suit easly with the firewall. Unlikely it will also the most pricely solution.

We will see, my cast wastegate adapter is allready shipped, so i will first see how i could fit it with my other parts. (and than i will buy an kinetic manifold)

Best Regards
Alleslowbuged

Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: BlueMule on December 12, 2011, 08:55:12 pm
Alles, what’s up?

321 is, DIN- X12CrNiTi 18 9, or ISO 683/XIII Type 15. It is universally used for high performance Turbo manifolds, and has proven its worth, viability and longevity. Also you want steel that can “glow red” and not break down over the long term, easy to work, and very available, again 321 fills the bill. 310, DIN- X12CrNi 25 20, is better in scaling at higher temperatures, but too ductile.

So I would use 321 because it is a known quantity. With your application, if you wrap your manifold and your adapter, it will glow red under the wrap, plain “steel” would never withstand this environment.
I am familiar with the chrome moly, 13CrMo4 steel, but 321 beats its heat resistance. I frankly would not worry about the expansion rate, 321 has been used for years with no spectacular failures I am aware of.
Whatever you decide, make sure your Merge Collector/Adapter has as little volume as possible, you want the exhaust flow high and the gas concentrated at this point, (obviously not to the point of restriction), but the less expansion allowed, (less volume) the more velocity and the more “agitated” the gas molecules, carrying their waste energy to the turbine.

I still think you should build a support for the turbo, and please don’t use a piece of galvanized electrical tubing (EMT) that has been beaten with a hammer flat on both ends and then had a couple of holes drilled in it, “Mein Großvater hatte das Luftfahrt-Maschinist würde entsetzt sein“. I mean really ???

The cast adapter, as long as it is using the right steel will be fine, the thickness of the walls will cetainly contain the gases easily, but again a support on the Turbo might help with the longevity.

I really am not too sure about that gasket matching, it seems as if the exhaust gaskets folks are getting now are wayyy oversize, it might be the photos, but I would not hogolicious the head to a size that overshadows the valve diameter. Better to make a set of gaskets, in fact, maybe I will project this and check gaskets from different suppliers, just to see.

Tell us about the cam if you could, lift, duration etc. vs stock.

As far as the valve seat, I am trying to envision where that angle would be, unless you mean the back side of the valve head. If so, this is a very common modification as it removes a huge disturbance to the air flow. In my world the valves come without this „notch“ and swirl polished back side and front. If I want that for my little Mule, I will have to machine it myself.

So wishing you the best

BlueMule

 
Title: Re: Golf II GTD with 1.9 AAZ engine --- performance camshaft
Post by: Alleslowbuged on December 13, 2011, 02:57:34 am
Hi, here the details from the camshaft, its a regrinded stock aaz camshaft


That is also the reason ,why i dismount the head in the golf and why i will install a 260°/250° camshaft.
lift is 9,9 mm / 9,4 mm, timming is 18°/62° - 57°/13°, spread angle 112°, valve lift in TDC 0,50 mm.

Best Regards    

Regarding the 30° chamfer, i has seen that on the original VW "Reparaturleitfaden" (repair manual), as it is the
stock mashining for the 1Z engine and yes it is behind the valve seat, but in the valve seat ring.

Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: RabbitJockey on December 16, 2011, 04:07:03 pm
like this?

(http://i94.photobucket.com/albums/l83/935racer/PICT2156.jpg)
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: NintendoKD on December 28, 2011, 05:27:13 am
LOVE THIS THREAD! :o
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: R.O.R-2.0 on December 28, 2011, 02:44:45 pm
the actual tubular part of your adapter looks like its made of 28ga sheet metal.. its all cracked, and looks way too thin to support a wastegate, let alone a turbo..

that was a really pretty piece too, shame they used such small tubing for the center part..

i would rebuild it, and use some thick wall steel rectangle tubing for the center section between the flanges..
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on December 30, 2011, 03:42:34 pm
Hi,

even if i don't have written hier something in the last day, it goes forward...

My hyper loved tuna can turbo adapter has used it last (sub 30 mph) 25 km to eliminate the last doubt that it is scrap:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00349.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00350.jpg)


All the scrap stuff is dismount allready, but i still wait for new parts.

Here are two pictures, which shows how a wastegate adapter should look like (it is for my BMW):

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00339.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00340.jpg)

 
The other adapter (T3/T25) will work in the golf, as it is smoth and tapered inside it schould be also positiv
for spooling:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00341.jpg)

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: carrizog60 on December 30, 2011, 04:00:32 pm
glad to see its moving.
that adapter as a stronger look,it it cast steel?
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on December 30, 2011, 04:09:02 pm
yes, both are cast
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on January 03, 2012, 04:12:44 pm
Hi,

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

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00369.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00370.jpg)


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):

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00374.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00380.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00382.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00383.jpg)
( 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)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00376.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00377.jpg)


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

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00386.jpg)

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)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00389.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00391.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00392.jpg)

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
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: carrizog60 on January 05, 2012, 08:06:18 am
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... :P
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: Alleslowbuged on January 07, 2012, 08:01:19 pm
Hi,

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

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: RabbitJockey on January 07, 2012, 09:57:00 pm
Come on!!!!!!!!!!  ;D
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on January 08, 2012, 03:32:13 pm
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.

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00393.jpg)

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)
  
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00394.jpg)

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:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00395.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00396.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00397.jpg)

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:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00398.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00399.jpg)

Today i have build a support for the new air filter:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00400.jpg)

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
  
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on January 11, 2012, 07:13:23 am
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
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: carrizog60 on January 11, 2012, 08:31:19 am
.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?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: Alleslowbuged on January 11, 2012, 02:37:16 pm
Hi,

here as start the original dyno plot:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Leistungsdiagramm_2-0bar_S2a_Golf-GTD_20120111.jpg)

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.)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Diagramm_Leistung_Januar-2012_20120111.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Diagramm_Drehmoment_Januar-2012_20120111.jpg)

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
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: MJF on January 11, 2012, 03:12:43 pm
Nice, next time 200hp? ;D
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: BillyWillicker on January 11, 2012, 07:14:53 pm
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?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: carrizog60 on January 12, 2012, 08:23:14 am
good to see that you got nice numbers!
were that hp figures what you were expecting?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: RabbitJockey on January 12, 2012, 08:55:53 am
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
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: baldone on January 13, 2012, 02:18:01 am
nice ;)
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Mark(The Miser)UK on January 13, 2012, 06:54:58 am
Hi,


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.

Best Regards
  

That rate of advance actually mirrors a standard vw 1.6TD pump.. . Just slightly lower but well within the range of usefulness because you wont runout of dynamic advance  at the higher speeds.
Do you have the dynamic advance curve readings?
Does anyone have a dynamic advance reading set for the yellow dot pump?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: Alleslowbuged on January 13, 2012, 05:12:05 pm
Hi Mark,

sorry but i do not fully understand your post, did you refer to the pump diagram if have posted in the "The Dynamic Advance thread...",
when you wrote "yellow dot pump"? If yes the stroke of the adavance timing piston is also shown in the diagram (lines with purple and
black cubes).

The diagram also shows that the max. stock internal pressure is ~8 bar @ 4500 rpm, by extrapolating the "linear" curve this brings the
stated ~10 bar @ 6000 rpm. The max. stock advance timing is ~9,5 °IP (@ ~8 bar), which brings ~ 7,0 °IP @ 6 bar, which says that my
timing actual works only proper up to ~3400 rpm.

Yesterday i have checked my pressure regulation valves whichs look and feel fine, so i will have to dismount the pump and take a look inside (again).
I have also installed the EGT gauge, but still have not found a proper place in the cabin (after it was taped in front of the instrument pack actual
it lays in the clove box.

I have also forget to write that i have dismount the pu inlays in the engine bearing, now everthing is fine again.

Best Regards
Alleslowbuged

P.S.
And also thanks for all that nice words, always nice to reconize that people reading this stuff
 

Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: Alleslowbuged on January 14, 2012, 12:14:17 pm
Hi,

today i finally found a solution for the EGT gauge and i am very happy with it:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00409.jpg)

Max. temperatur until now was 960°C (1760 °F) in fourth gear @ ~4800 rpm with full load, at normal accelaration it is between 350 - 500 °C (660 - 932 °F), idle temp is around 120 °C (250 °F).

Here two pictures from outside, becuase we did not have one for so long:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00407.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00402.jpg)

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: carrizog60 on January 15, 2012, 04:42:29 am
looks good!

as for the gauge why not in the vent area?
or make a custom plate to replace the area where the lighter is?
i have 2 gauges there and it looks great,almost oem.


as for timing,do are you sure the advance rate is linear?
you could try to make less pre-tension on the spring so it would advance faster?(less internal pressure but compensated with less spring resistance)
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: Alleslowbuged on January 15, 2012, 07:48:56 am
Hi,

yes vent area would be an option, but i wand it as much in my driving view as possible.

Regarding the timing, i will see what i will do, after i have took a look inside the pump.
The timing curve is not 100% linear, but nearly so it is not necessary to considere.

Best Regards
Alleslowbuged

 
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: theman53 on January 15, 2012, 09:54:55 am
I would say your pump is putting out almost what mine did. I had mine turned down but it would still get to 1650F and I would let off. You aren't too worried about the heat? I told Giles last time just to make it run and I would not worry about it. How often have you gotten it that hot? I really want to get my engine back together and see how hot I can make it without melting.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: Alleslowbuged on January 15, 2012, 11:30:13 am
Hi,

my BMW have sometimes more than 1000°C (>1830) when i make full load through serveral gears (i.e. on 1/4 mile race) and it did that for serveral years now.
But i have to say that such high temperatures just occurs for seconds in both cars. I am personally not to much scared up to 800°C, as i read that actual TDI
have that at full load on the autobahn also.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: carrizog60 on January 15, 2012, 02:09:42 pm
is tdi head the same material as ours?i dont think it is,being a late technology ???
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: Alleslowbuged on January 19, 2012, 08:32:26 pm
Hi,

today i have made some comparison with the "EVO I" vs. "EVO II" figures, here is whats came out:
(straight line is "EVO I" and dotted line is "EVO II")

wheel power vs. speed:
(black line is drag power)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/wheel-power.jpg)

wheel power (minus drag) vs. speed:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/wheel-power_minus-drag.jpg)

wheel torque (minus drag) vs. speed:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/wheel-torque_minus-drag.jpg)

acceleration vs. speed:
(max. acceleration in 1. gear is only theoretical)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/accelaration.jpg)

speed vs. time:
(i assume max. possible acceleration due to wheels is 0,7g, no shifting time)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/speed-vs-time.jpg)

distance vs. time:
(i assume max. possible acceleration due to wheels is 0,7g, no shifting time)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/distance-vs-time.jpg)

Best Regards
Alleslowbuged


 
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: TurboJ on January 21, 2012, 03:59:36 pm
Great stuff! I love all the analytic stuff too!

I'd love to hear how it actually behaves on the road, is the turbo boost readily available for overtaking for example, or is there a noticeable delay after you press the throttle - when driving in the right rev range of course.

How is it off-boost? Would be very interesting to hear how the "normal driving range" of the AAZ's performance has improved.

Thumbs up for your great progress and determination!

You'll be getting some very, very impressive hp number in the future when you get it running 100% (and maybe with a front-mounted intercooler...)

I'm definetely watching this space!
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: Alleslowbuged on January 22, 2012, 07:24:32 am
Hi,

Thanks for the nice words, the "normal" (non blast) driveability is great, a shame for VW that the did not cut valve pockets in the pistons or deepening the valve seats (as i did) to be able to put in a "real" camshaft. As could be seen in the dyno plots, i have now 20 Nm - 50 Nm and 8 kW - 20 kW more in the rev range 1000 rpm - 3000 rpm, which is mainly related to the camshaft in my eyes. And in fact this not a suprise for me, because our idi engine did not need a specific swirl due to valve geometrie and flow speeds, as it makes all that neccessary pre-combustion work in the swirl chamber, so in my eyes the valves has only one thing to ensure: to max. out the possible flow.

In my eyes it is the logical consequence, if you take the efficiency penalty from the swirl chamber, you should also take the advance from them, that you could take the biggest valves (only limited due to mechanical and geometric limitations) and try to use the higher temps in the swirl chamber for higher revs.

To come back to your question, the off-boost performace is improved to. The new "drive feel" appeals me more with every km i have driven (actual ~ 1300 km) it. It is quite differend as before, every minimal throttle move brings a tiny slighty boost increase at low idle, so the engines allways feels motivated to give more. For sure it is everything else than a K14 setup, whichs warps you through lower revs with instand response.

It feels a bit less spectacular, as the "boost hammer" came at ~ 1,0 bar instead of ~ 0,5 bar (with smaller turbos), so you allready have say 120 hp when it comes really hard. But as i say before and could be seen in the dyno plot, i have allways and anywhere more power than before.

What is really really nice now is the "non cruising mode", and is not only due to the improved power figures it is due to the improved shape of the power curve. I can stay as long as i wand in every gear through a corner and it still is capable to pulls me out of the corner harder and harder as the power allways increase. We have had a small blast yesterday (a friend with a 330 D (E46) and me) and i really like the way how it works know, specially whith the open screamer pipe, whichs gaves a great secondary acoustic signal, just like an acoustic  redline flash.

But there was also some poor moments yesterday, i have bought a 5,0 V10 TDI intake whichs looks exactly how i wand my intake manifold to look:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00414.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00415.jpg)

The ports has the correct geoemtric in general, but the support bolts are not on the right place. I also needs ~ 110 mm lateral place and i have only ~85 mm between the cylinder head and the compressor housing. How ever i have hoped to find a solution by unsing the support flange from a 1Y manifold:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00418.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00419.jpg)

In fact i must cuted the V10 manifold, so that it is mainly only a pipe at the end. As result i notice that the runners than have a smaller axial distance (the two inner runner are connected there) so they will than not fit with the 1Y part. Pherhaps i could weld the two 1Y parts together in a differnd angle, so that they will fit with my turbo setup, but than i also have change the angle on the top end of the manifold. At this burning of money depressed me yesterday, i did not have make any more pictures and have decided to bold on a stock 1.9 TDI manifold (the version with seperate runners) as first step.

Best Regards
Alleslowbuged



   

 

           
         
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: RabbitJockey on January 22, 2012, 09:37:35 am
Perhaps u could just weld on a boss to the side of the ports that is missing the bolt hole or you could even have a flange made up and weld the v10 it take to that the flange idea is costly for sure. But it sounded like you wanted to make very short runners right?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: Alleslowbuged on January 22, 2012, 12:49:41 pm
Hi,

yes the flange idea would be possible, i have had thought about it also before i cut the 1Y intake in two pices.
I have tried to stay with the runner length of the V10 intake (also with the different in lengths from 1. to 4. cylinder),
but the part which i cut out of the 1Y manifold is nearly the same length as the V10 runner for the 4. cylinder.

I have also tried to stay with the angle of the V10 runners, but both together means that there will be a collision with
the compressor housing. After leaving the frustration phase behind me, i am now not longer sure that there is no chance
to use the V10 intake. If i would have started with the idea to change the angle of the runner to that degree that it fits with
compressor housing, and take the 1Y part as additional runner lenght, there could be a change to build a nice intake, with
reasonable effort.

Best Regards
Allelsowbuged   
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II (new dyno)
Post by: baldone on January 24, 2012, 01:43:51 am
Hello

If it is not a secret, could you send me a dimensions of the intake manifold?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on January 26, 2012, 03:50:01 pm
Hi,

@baldone
Sure you get that, but i have to took them out of the 3D model before. Also iwand to state out, that the stock intake part is only make with rough dimensions and do not realy relate with the real stock intake, so i am not sure if can do anything with the dimensions.

@all

Here is a short video for the fans of moving pictures, which schows acceleration in third gear from today with speedo, rev counter and boost gauge. You can also see the egt gauge, but the display refresh time did not fit with the cam picture rate:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/th_Drehzahl-vs-Ladedruck-2.jpg) (http://s702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/?action=view&current=Drehzahl-vs-Ladedruck-2.mp4)

Best Regards 
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: baldone on January 27, 2012, 03:32:55 am
Thank you!
The rough dimensions are enought for me!
Best regards Sanya
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on February 12, 2012, 03:01:16 pm
Hi,

i have just drove it the last few weeks, to cold for working in my small unheated garage. All together i have ride a bit less than 2 t km.

we have made some new G-Tech runs last weeks and after two year of wating for breaking the 15s amrk i have done a 14,909 s ( a bit downhill, so in fact it is still something around 15,0 s :-[) The best run was done with start in second gear, but this is nothing what my clutch likes, but otherwise i did not get any traction in first and second gear.
I would assume that i could get a bit faster at higher ambient temps, because the grip level at ~ - 10°C with sommer tires is a not high as it could.

here are the stats:

200 m (1/8 Meile) 9,8 s @ 126,9 km/h
400 m (1/4 Meile) 14,9 s @ 152,9 km/h


0 - 100 km/h 7,60 s ( 6,90 s mit 30cm Rollout)
0 - 120 km/h 9,60 s ( 8,90 s mit 30cm Rollout)
0 - 140 km/h 13,10 s (12,40 s mit 30cm Rollout)
0 - 160 km/h 17,05 s (16,35 s mit 30cm Rollout)



40 - 80 km/h 2,39 s
60 - 100 km/h 3,36 s
80 - 120 km/h 4,16 s
100 - 140 km/h 5,53 s


We have also measured a BMW E46 330D with a 5-speed-auto, which is f..cking fast for its 1700 kg. In fact it has the same time on the 1/4 mile, as my VW with (nearly) equal power and 700kg less weight. The G-Tech shows that the acceleration does not rise below 0,3g during shifting from second in third gear, while during my manuell shifting is rise always down to 0,05g.

At least my T3/T25 adapter cracks again today, i have allready bough another one, this time from the UK which is again stronger than the one before. It seems that the new adapter is from the same manufacturer than my T3/T3 adapter, whichs also cames from the UK. Unfortunately the did not offer this type a few weeks ago.

As an intermediate conclusion i have to say that i am really confident with the update overall and that i love the new engine characteristic, which it spectacular upper top end.
  
Here are two pics, were the crack can be seen:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/PICT0152.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/PICT0153.jpg)

Best Regards


P.S. If i am not to lazy i will post some G-Tech pics later (Golf und E46)
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on February 19, 2012, 05:11:18 pm
Hi,

just as short update, i have dismount the turbo and the cracked adapter yesterday and have to notice that the adapter was fully broken in two parts:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00422.jpg)

The other side is also 70% cracked.
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00424.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00425.jpg)

It seems as the crack has started from edge due to the mashining of the bold backface. However i have allready
a new one, whichs seems a bit stronger but will cause some space trouble again. Pherhaps i have an issue with
my exhaust system due to the new flexpipe. I think i will install an additionally support just behind the flex pipe.

Best Regards
Alleslowbuged   
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: vanbcguy on February 19, 2012, 09:37:32 pm
I can totally see a lot of that cracking happening if the downpipe doesn't have enough support against the block.  The adapter would take the most stress for sure.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: theman53 on February 20, 2012, 09:00:46 am
If you brace it before the flex, as in downpipe to the block, since that should never move, you shouldn't have anymore issues.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on March 04, 2012, 05:15:24 pm
Hi,

so no big news here, but i could figure out a contact at schwitzer in the states who was so kind to look for a compressor map for my turbo and finaly find one from 1992 (not 100% the right one, because the compressor cover is slighly different) and pass it to me. I plot my matchbot results in and here is it:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/S2A_mit_Matchbot-Punkte.jpg)

I think it is quite a good match, even if it is very close to the surge line, but in my mind it has very good efficiency rates (>68%) for the high pressure ratio. At least it was 90% luck, as i bought it from ebay without any specific technical data, just because it was from switzer (inconel turbine wheels) and at a resonable price.

Best Regards  
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on March 11, 2012, 05:59:36 pm
Hi,

again just a short update, i have start to reassemble the engine today.
The main issue is to find a solution for a downpipe support, at least i decide to use a flat bar and use one of the supporting screws of the gearbox at fixing point on the engine side. At the pipe side i will use an additionally U-clamp.

Here is the a picture fo the engine side:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00458.jpg)

here is an overview picture (the additionally U-clamp is missing and i have to increase the bend angle of the flat bar)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00457.jpg)

Here is a picture with the scrappy stud bolts i have bought, they have only 8mm thread on the engine side, which is not engough for a M8 stud bolt in alu. Also the area without thread is extrem long, therefore the stud bolts are to long for my manifold.

Best Regards
Alleslowbuged 
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on March 12, 2012, 11:54:48 am
that compressor map is pretty good, has it ever surged for you?  looks like at your boost pressure it stays above 68% until about .17 kg/s which is about 22 lbs/min so it should be good for around 220bhp
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on March 12, 2012, 02:36:05 pm
Hi,

as i am not a surge expert, in fact i did not know.
But besides the first drives without active wastegate and approximate something around 45 psi boost, i think not that i have seen surge once.
With the active wastegate i have never notice a strange noise or performace shortfall, without the active wastegate there was a performance
shortfall somewhere above the 3x psi range (~4000 rpm) for arround 500 rpm before performance came back. I would assume that this was
surge, but with the special engine bearing i could not hear anything at that time.

Best Regards       
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on March 18, 2012, 05:42:09 pm
Hi,

i put everything together last friday and start the engine shortly, just for motivation.
Main issue was to complete the downpipe support, but finaly it should be as felxible as necessary (thermal movement) and as rigid as possible:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00461.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00462.jpg)

I have also bought some "high pressure" clamps for the boost pipes:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00460.jpg)

Here is a picture from the front where the PD intake could be seen, i still waiting for a "race pipe" to be able to find a boost pipe between the intercooler and the intake.

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00463.jpg)

As next i modified the heat protection plate an bolt it on the intake:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00466.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00467.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00465.jpg)

Here is a pic with the new breather filter:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00468.jpg)

And last but not least i have installed an additionally fan for the intercooler, i hope to prevent that the water
cooler fan heat up the intercooler, when the car stands (e.g. 1/4 mile start)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00469.jpg)  

I hope to get the race pipe next week and be back on the streets than.

First thing than will be to further increase the internal pump pressure to 3,0 bar @ 1000 rpm wihtout the
small electrical feed pump (increases pump internal pressure @ 1000 rpm ~0,5 bar), actual i have 2,5 bar
@ 1000 rpm with the feed pump runing. I hope to came close to 9-10 bar @ 6000 rpm with the change, which
should bring a bit more top end power above 4000 rpm.

I would like to dyno it again after that and see if the pressure increase and pd intake will bring any power
increase too. That time i would make three runs with different boost pressure (1,0 bar; 1,5 bar and 2,0 bar), will
be also interesting to see power output with 1,0 bar.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on March 22, 2012, 04:56:32 pm
Hi,

today i have start to install a front splitter:

before:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/vorher.jpg)

between:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00471.jpg)

after:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/seite-1.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/VORNE-NEU-3.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/VORNE-NEU-2.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/VORNE-NEU.jpg)

The splitter must be landed with two M6 bars, but unfortunatelly they send my the short verison, with is not useable
at the mk II.

I was afraid, that it would look more awkward, but anyhow it will definitely massiv decrease lifting at the front end and
pherhaps even produce downforce.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on March 24, 2012, 07:33:58 pm
Hi,

i think i will swap to a NA, because the sound so nice:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/th_MOV00486.jpg) (http://s702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/?action=view&current=MOV00486.mp4)

today i have again change the front bumber setup, because i could not leave my garage:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/vorne-16V.jpg)

Now i have installed the splitter with the normal front spoiler instead with the 16V version. I like that it is a bit less flashy, but i also think that the downforce efect will be less than with the 16V front spoiler:


(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/vorne-neu-11.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/seite-und-e28.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/seite-2.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/detail-2.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/detail.jpg)


Best Regard
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on March 25, 2012, 10:05:51 am
I like the splitter on the normal spoiler better it's more subtle perhaps painting the supports black would help too,  but that is assuming you like subtle also
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on March 28, 2012, 04:56:20 pm
Hi,

Hallo,

its running again::

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00537.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00538.jpg)

Unfortunately it was not as easy as i hoped:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00533.jpg)

i have ask the seller if the race pipe will fit 100% and he say yes. Anyhow i bit drill a bit cutting and a set of washer and it fits (for the moment):

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00534.jpg)


I have also weld a m8x1 nut on the pipe, to conect my pressure hose:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00535.jpg)

the pipe is also to small, it should be d Ø57 mm / D Ø60 mm and it is d Ø50 mm / D Ø53mm:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00536.jpg)


Here a picture puzzle for the experts::

what is wrong here (measure internal pump pressure)?
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00539.jpg)

and whats differend here?
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/schraeg-hinten.jpg)

I have adjusted the internal pumpe pressure from 2,0 bar @ 1000 rpm to 3,0 bar @ 1000 rpm, so now i get ~8,0 bar
at redline. Here are two videos how the pressure reacts versus speed:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/th_Pumpeninnendruck_2-0-bar.jpg) (http://s702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/?action=view&current=Pumpeninnendruck_2-0-bar.mp4)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/th_Pumpeninnendruck_3-0-bar.jpg) (http://s702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/?action=view&current=Pumpeninnendruck_3-0-bar.mp4)

@Trev0rbr
Yes, from the optical point i also like it more with the normal spoiler and also yes a bit black paint would help. 
Gruß Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on July 30, 2012, 03:25:53 am
Hi,

there are some bad news from here, as the head gasket can not handle 30 psi boost with my unplained cylinder head, so i think i have to lift the head again and plain the cylinder head, as my soldering is still absolute fine. The head gasket ist 100 % tight with only 1,0 bar boost and also with 1,5 bar bosst if i not rev it above 4500 rpm.

But there are also some good news, as i swaped the turbo again from the schwitzer S2A to a S100, which matches even a little bit better than the S2A. I make the hole conversion at one day (~ 8 hours), during waiting for the postal guy who pick up a packet from me.


The turbine casing from the S100 is a bit smaller than the one from the S2A and the compressor casing is anti-surge.
Here are few comparison pictures:

(left is the S100)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00429.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00431.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00437.jpg)

The main reason for the swap is that i shedule to use the S2A in my BMW 524 TD, but i also want to just try how the S100 would match since a while.

Here are a picture witht he compressor maps of both plotted in the same diagram
(red is S100; black is S2A)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/S2a-vs-S100_mit_Matchpoints_20120415.jpg)

I also plotted the boost lines in for both, which i have calculated with the BorgWarner matchbot. the points are related to 2000rpm, 2500 rpm, 3000 rpm, 3660 rpm, 4446 rpm und 5000 rpm from left to right. The blue line is AAZ with S2A, the brown is AAZ with S100 (a bit assumed) and the green line is BMW M21 with the S2A

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/S2a-vs-S100_mit_Matchpoints-3_plus_BMW524_20120513.jpg)

I also rechecked the internal pressure of the IP again and find out, that it has again 2,0 bar at idle and not the 3,0 bar i adjusted in march. I wonder if this will be due to the viscosity change because of the higher temps, but i do not now. I did not change it, because i could see a clearly relationship between headgasket stress and high internal pump pressure (early injection). I also rechecked the ARP stud bolt tension and find them all in line with what i torque them down during installation.

Because i could not find somebody who make my rims legal i have to swap to different set:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00837.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00838.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00839.jpg)

Wenn i bought them, they have slicks on it, unfortunatelly only two of them was leakproof, so i put two to my old rims for further drag strip races.

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC00840.jpg)


What come out very good is the fuel consumption i get between 35 and 39 mpg with the last fillings.

Last but not least here is a new short video from yesterday, with only 1,0 bar because the boost-controller did not work that day and only rev it to ~4500 rpm as the headgasket is not bulletproof:
(the driver most likes the part uphill from 3:25 min bis 4:30)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/th_Golf-2_GTD-AAZ_2012-1.jpg) (http://'http://s702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/?action=view&current=Golf-2_GTD-AAZ_2012-1.mp4')

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on July 30, 2012, 11:09:53 pm
That turbo looks to be a bit of a better match.  How different does it drive?  Do you have better low end power?
What did these turbos come on?  Seems like in the us schwitzer stuff was only available on John Deere tractors in huge sizes.  I guess kkk, schwitzer, and borgwarner are all one company now.  I don't know what all is available in Germany but the Garrett t3 stuff is everywhere here with lots of options, and still efficient enough to be relevant imo, most of them are efficient at higher boost since they all have a decent sized exducer of 60mm.  And on the exhaust side there's tons of combinations of turbine wheels and housings.  And you can even drop down to the t25 exhaust sides that are more efficient.  But that's just my input if you want to play with turbo sizes.  The right t04e might even work since you have a ported head aaz
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on August 05, 2012, 05:09:29 pm
Hi,


today was a realy good day, as i was on a 1/4 race event and could make some good runs, at least for me. I did 6 runs overall and could improve my time with each run.
Because my electronic boost controller stop working for me from time to time, i build in a secondary manual valve yesterday, which was a good idea, because i needed it
after the second run.

 
My first rund was with 1,5 bar (~22 psi) and i good not change in fourth gear, so i started with a 16,9 second. As i write before my headgasket has had massive leackage with high boost for a couple of weeks, but i drove the car very carefully since than and now it seems to be captable to seal (what i did not understand), as there was no high pressure after the first run i increase boost pressure to 2,0 bar (30 psi) for all further runs. My second run was a 15,8 s which is very similar to what i make last year on the same track with my BMW. Through the next runs i improve the time by approximate 0,1 seconds per run and ended up with a 15,4 s what is my best time for that track overall. Top speed was ~145 km/h with the Golf, last year with the BMW i achive 152 km/h.

From run 4 to 6 i did not preserve the engine any longer and run very slighty above 2 bar and rev it like hell in the first two gears (~5700-5800 regarding rev counter) and as i write early i could detect any headgasket leackage.

I only was anoyed because i did not bring my slicks with me, because i did not assume the car will run without problems and would not be there with slicks and 17 seconds time. But next weekend there is another drag race (1/8 mile) were i will start, so if the weather is with me i will try the slicks there.

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on August 05, 2012, 05:14:22 pm
Hi,

here are three video i find on youtub:

first run vs. BMW 123D (204hp), i make a shift error (loose with 16,95 s)
(from ~1,02 min)
http://www.youtube.com/watch?v=J3SN3i8-kjE

second run, vs. same BMW 123D (win with 15,8x s)
(from ~ 7:33 min)
http://www.youtube.com/watch?v=4o9UVixqHC0

fourth run, against Passat (177 PS) (win with 15,7 s)
(from 0:00 min)
http://www.youtube.com/watch?v=Uo_FlEt-gE8

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- crack - soldered - running
Post by: baldone on August 12, 2012, 07:45:21 am
Hi,

i have one of these and have had scheduled to use it on my rabbit project, but this was cancelled because of the D-port-shape of the na intake.
I have not found a pipe -  td-intake arangement, which convinced me really, so i allready have considered to make a simulation with the na intake.
Problem is, first that i am not sure were i have it and second that i do not remember if that the na intake will make collision with the turbo.

Yesterday i have ordered a new stock engine bearing and a additional PU inlet:
http://www.clausvonessen.de/pi22/pd49.html

I have also odered a few Ø80x2 alu pipes and a few Ø120x5x500 alu flat sheets to make the tapered intake pipe from (either for td or na intake part).

This is what seems to be best, but is to much for for manufacturing (for me)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Special_Inlet_Manifold_0-2kg-s_R08_20111204-3D.jpg)

This is what i end up with:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Special_Inlet_Manifold_0-2kg-s_R12-2_20111205-3d.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Special_Inlet_Manifold_0-2kg-s_R12-2_20111205.jpg)

But as i wrote, if the na intake will fit i will take it.

Best Regards  

is this made with solid work?
Can you send me the file in e-mail?

Thanks a lot!
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on August 13, 2012, 03:31:12 am
Hi,

@baldone
i have to look how big the file is, but if it is within my email range, sure i can send you the file.

@all,
I was on a 1/4 mile drag race last weekends and after one 1,5 bar run, to check how the headgasket answer, i could make serveral 2,0 bar runs without any problems and getting quicker with each run. After six runs i could achive a 15,4 seconds, better time was not possible because the CTN gearbox has not good ratios for 1/4 mile runs. If i could start in second, what is not possibly yet, due to the clutch) it would be a good fit, but otherwise not.

Yesterday i was on a 1/8 mile drag race and did 16 runs without problems, so the "soldered-head--leakage-headgasket-wonder" goes on. I started with slicks in early morning and could achive a 9,4 seconds, what was my best run overall. In the last run my rev counter stops working, but now it working again but sometimes show strange values.

Best Regards
Alleslowbuged 
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on August 13, 2012, 03:50:14 am
@baldone

the file is quite big (>7 mb) but i allready send it to you.

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: baldone on August 24, 2012, 11:24:11 am
@baldone

the file is quite big (>7 mb) but i allready send it to you.

Best Regards

thank's  ;D
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: MJF on August 25, 2012, 03:48:57 am
What headgasket are you using?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on August 25, 2012, 12:46:28 pm
Hi,

stock Reinz MLS gasket (three notch).

I have been on serveral quick road trips in last weeks each one to two hours on twisty roads and have very stable temps and no leackage, so it realy seems like the gasket has resealed itself. :D

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 05, 2013, 04:06:07 pm
Hi,

long time ago that i posted something here and up to last Monday i did not have done anything on the Golf, just driving driving driving. I think my headgasket is still in good shape, but my soldered head is leaking again. If i limit my boost pressure to 1,2 bar (17,5 psi) and only rev to ~5000 rpm it is not an issue at all, i just have to refill 1 ltr. coolant fluid per month. But when i go for full boost of 2,0 bar (30 psi) and rev up to limit, then i spit out a lot of coolant fluid in a short time. It seems, that the crack is to small to led fluid pass, but is big enough to led gas pass through the wall. So when i go for 30 psi boost, this also means that i will a ehaust pressure of ~30 psi, whichs pumps exhaust gas into the coolant system, so that the pressure blow off valve opens.

Anyhow, i did not post here to bore you with my leackage issues. It is much better, i put the BIGGEST TURBO AS POSSIBLE on my AAZ, but one step after the other:

After month without sunlight and sub zero temps, the weather was good last monday i need to do something which should bring some fun, so i decided to swap the turbo on my golf.

So first the Switzer S100 needs to go:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0420_zpsb490184a.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0421_zpsdc03e6a7.jpg)

than looking for something different:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0423_zps75d901ef.jpg)

The left one is a china GT2052V, but there is not have enough space in the engine bay for the actuator can. 
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0422_zps4a6a05ed.jpg)


So i disassemble the exhaust side i look how i could rotate the bearing section "one screw" to make it fit. It would be necessary to drill three addtionally holes in the exhasut casing, but before i could start to do that, i dump down the disassembled turbo and it land on the exhaust blades ???
So i think it is not longer useable, anyhow here are some more pics whichs shows the less than optimal built quality of the turbo:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0432_zps9e60e022.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0426_zps1d8e98fe.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0429_zps2bed55af.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0430_zps1a18c11f.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0431_zps350f18f2.jpg)

here are two pics of the vtg mechanics
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0433_zps6dd52491.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0434_zpsa359a87c.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0427_zpsf19c05cb.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0428_zpsedd9c77b.jpg)


As i write the weather was good i wand to have something new, so i look what else is availabel:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0439_zpsd99877a0.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0440_zps4de867cf.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0441_zps5f9afb1e.jpg)

Its a Schwitzer S2B TwinScroll and it is way to big for a 1.9 TD engine, but i always wand to know how it feels to have a turbo, which is so big that no wastegate is needed and so will cause the lowest possible exhaust pressue. Anyone here wis a bigger Turbo?

I only drive a short round, but it is really a differnt world, i did not have driven a TD, whichs feels equal. First there is the 1.9 NA torque, than there is nothing (should be possible to improve that with a little less LDA preforce), than around 3000 rpm the turbo starts to spool and boost rises up to 0,5 bar (8 psi) and from there boost continious rises with rising boost up to approximate 1,0 bar at redline, all wihtout wastegate action. It is obvious that the car is slower than before, but it is not slow in general, due to the linear gasser power curve it is very difficult to subjectiv estimate the power, but i will go to dyno as soon as possible.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 05, 2013, 04:17:28 pm
Hi,

i forget the final pictures:


(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0442_zps544a6a07.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0443_zps7a1858c8.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0444_zpsf48f5f62.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0445_zps5ceadfc6.jpg)


Best Regards
Alleslowbuged 
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: carrizog60 on April 05, 2013, 06:15:53 pm
only 1 bar at redline?thats big lol
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 06, 2013, 05:34:45 pm
Hi,

i fixed the downpipe issue today and replace the front engine bearing. Afterwards i could do another short test run (did not have had enough time) and i have to revise my last post, the max. boost of 1,0 bar was with slightly wastegate action, i just did not here it. Today i have seen 1,4 - 1,5 bar at redline of third gear. I think i really appreciate the "huge turbo feeling", the rush when the turbo kicks in above 0,5 bar really feels good, the engine feels very free and joyful to rev (for an AAZ).

I am very inquisitive to see a dyno plot from this setup, a friend follow me with his 325 TDS today and during 2. gear and in third gear with boost level below 0,5 bar he could keep up, but then he get's very soon very small in my rear mirrow, so peak power should be not so low.

Best Regards
Alleslowbuged   
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on April 07, 2013, 08:10:37 am
http://www.vwdiesel.net/forum/index.php?topic=4792.0;
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 07, 2013, 06:03:49 pm
Hi,

thanks for the link. I have read all the 24 pages and not all of them was very rich in content, but it is a very cool thing in general. I find the quick spool valves some years ago and from time to time i think about it and want to have one, but not in the last couple of month. Today i ended up with ordering one of the valves from sound performance, even if they are way overpriced in my eyes.

So next step is to dismount my wastegate (nor more need with the big turbo) and put in a blocking plate with a hole for my egt sensor, i am feeling like blind without egt reading in the moment. After you getting used to have one, it feels very rude to squeeze an engine after modifing it and do not now what egt will be the result of the mod and than dyno.

Best Regards
Alleslowbuged   
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on April 08, 2013, 07:42:17 am
i just wound the first thread that discussed the quick spool valve because i thought u may be interested and that it it could help with the flat spot in power.  should be interesting.  i may have missed it, have you fixed the leaking head again?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 08, 2013, 09:33:39 am
Hi,

no it is still leaking, but i do not longer think that the headgasket is the problem, i think it is the soldered crack in the exhaust port of cylinder four. It is leaking, yes, but it is not so bad that i could not drive the car. It is leaking since several month i use the car as daily driver over the hole time, if i drive like a normal dirver is nearly no issue, only when i drive it with high boost and/or really high revs i have to fill up coolant from time to time. When the car is runing there are no signs of water steam at the exhaust, so it is not so much. If i drive the car hard and then park it, wihtout relief the pressure from the coolant system first and than wait a few days, than it will have a certain amount of water in the exhaust, which causes a bad black spot on the tarmarc during start up.

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on April 08, 2013, 12:12:17 pm
a problem u can still drive with seems to be how vws break.  its probably cracked in the best place possible for such a crappy thing.  :P
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 08, 2013, 12:25:24 pm
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0454_zps964daf42.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/7e26a404-24ed-421f-8078-a4be9100d395_zps322fee7e.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0455_zps5da194f6.jpg)
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 08, 2013, 04:02:52 pm
Hi,

today the turbo was only good for 1,0 bar (15 psi), and here for all how wants do know what "turbo-lag"  means:

(all data in fourth gear)

0,10 bar   bei  90 km/h  (2350 rpm)
0,20 bar   bei 100 km/h (2600 rpm)
0,50 bar   bei 140 km/h (3600 rpm)
0,75 bar   bei 165 km/h (4300 rpm)
1,00 bar   bei 190 km/h (5050 rpm)

The dyno was not strong enough to allow the turbo to spool up the whole way. But for only 1,0 bar the peak power was quite good in my eyes. To mount the S2B on the AAZ was only a crazy idea at the begining, but now i think it could be worth the try. If the QSV works only 50% as i hope, this should be a real competitive turbo and i will not install any wastegate in my engines again.  

here is a small video from the first dyno run:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/th_MOV_0458_zps454491b5.jpg) (http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/MOV_0458_zps454491b5.mp4)

dyno plots to follow later

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: carrizog60 on April 08, 2013, 04:45:22 pm
how does it drives before turbo spool?
and how did you like the s1 series?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 09, 2013, 01:42:30 pm
Hi,

@ carrizog60
Without boost it drives like a NA engine.
I have liked both smaller Schwitzer turbos a lot, the S2a was good for a bit more peak power and the S100 should be the best daily driver, non vtg turbo for an tuned 1,9 TD i know.

Here now the dyno diagrams:

first run:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Leistung_1bar_S2B_20130408_zpsbde029d9.jpg)

Because the shape is a bit weird above 170 km/h, we had make a second run. It does not sound or feel, if the power was decreasing increasing and i also could not feel that during my test runs on the street, so pherhaps there was a little bit wheel spin on the dyno.

second run:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Leistung-2_1bar_S2B_20130408_zps71623fb6.jpg)

and here as comparison with the older dyno results:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Leistung-alle_zpsc52e316c.jpg)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Drehmoment-alle_zps816c6375.jpg)

and as numbers:

175 hp bei 5360 rpm @ 1,0 bar
253 Nm bei 4450 rpm @ 1,0 bar

For sure power is less as 190 hp, but for only 1,0 bar boost pressure  iwas really surprised from my small engine with the big turbo. Above 5000 rpm it is nearly the same power as with the smaller turbos and 2,0 bar boost pressure. The dyno results in mind i can imagine that there was 200+ hp during my test run on street with 1,4 bar boost pressure. I am excited as a child to get the QSV and try how it works.

Best Regards Alleslowbuged   
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 09, 2013, 02:24:44 pm
Hi again,

some more data to follow. I have get the compressor map from Schwitzer yesterday:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Schwitzer_S2B_Compressor-Map_20130409_zpsd6c33165.jpg)

The compressor is capable for full 3,0 bar (43,5 psi) boost pressure and according to my match bot calculation i end up in the area with the best efficiency at peak power.

here are the map with my calculated points, according to the dyno run:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Schwitzer_S2B_Compressor-Map_dyno_20130409_zps1950a2a9.jpg)

Best Regards
Alleslowbuged

P.S.
here is the link to the match bot calculation:
http://www.turbodriven.com///////performanceturbos/matchbot/index.html#version=1.2&displacement=1.9&CID=115.938&altitude=500&baro=14.502&aat=75&turboconfig=1&compressor=62k80&pt1_rpm=2350&pt1_ve=90&pt1_boost=0.145&pt1_ie=95&pt1_filres=0.08&pt1_ipd=0.2&pt1_mbp=0.5&pt1_ce=65&pt1_te=75&pt1_egt=480&pt1_ter=1.03&pt1_pw=12.77&pt1_bsfc=0.34&pt1_afr=16&pt1_wts=300&pt1_wd=83&pt1_wd2=74&pt1_wrsin=69033&pt2_rpm=2600&pt2_ve=90&pt2_boost=0.29&pt2_ie=92&pt2_filres=0.1&pt2_ipd=0.2&pt2_mbp=1&pt2_ce=70&pt2_te=73&pt2_egt=790&pt2_ter=1.03&pt2_pw=11.31&pt2_bsfc=0.34&pt2_afr=16&pt2_wts=320&pt2_wd=83&pt2_wd2=74&pt2_wrsin=73635&pt3_rpm=3600&pt3_ve=90&pt3_boost=7.25&pt3_ie=92&pt3_filres=0.12&pt3_ipd=0.4&pt3_mbp=1.3&pt3_ce=73&pt3_te=72&pt3_egt=910&pt3_ter=1.39&pt3_pw=1.1&pt3_bsfc=0.35&pt3_afr=16&pt3_wts=340&pt3_wd=83&pt3_wd2=74&pt3_wrsin=78238&pt4_rpm=4300&pt4_ve=88&pt4_boost=10.875&pt4_ie=90&pt4_filres=0.15&pt4_ipd=0.5&pt4_mbp=1.5&pt4_ce=70&pt4_te=73.5&pt4_egt=1100&pt4_ter=1.52&pt4_pw=NaN&pt4_bsfc=0.35&pt4_afr=17&pt4_wts=368&pt4_wd=83&pt4_wd2=74&pt4_wrsin=84681&pt5_rpm=5050&pt5_ve=82&pt5_boost=14.5&pt5_ie=80&pt5_filres=0.18&pt5_ipd=1&pt5_mbp=1.8&pt5_ce=69&pt5_te=74&pt5_egt=1150&pt5_ter=1.7&pt5_pw=0.08&pt5_bsfc=0.37&pt5_afr=18.5&pt5_wts=400&pt5_wd=83&pt5_wd2=74&pt5_wrsin=92044&pt6_rpm=5050&pt6_ve=82&pt6_boost=14.5&pt6_ie=80&pt6_filres=0.18&pt6_ipd=1&pt6_mbp=1.8&pt6_ce=69&pt6_te=74&pt6_egt=1150&pt6_ter=1.7&pt6_pw=0.08&pt6_bsfc=0.37&pt6_afr=18.5&pt6_wts=400&pt6_wd=83&pt6_wd2=74&pt6_wrsin=92044& 



Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: carrizog60 on April 09, 2013, 05:15:41 pm
too bad for the lag...
looks to be a good turbo for a twin turbo setup!
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 09, 2013, 05:23:31 pm
I think lag will be ok with the quick spool valve and than it is nearly a twin turbo setup, but time will tell us.

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on April 09, 2013, 08:35:54 pm
I wasn't impressed until I realized this is at only 1bar.  Very impressive and what a fun thread the way you have recorded all this data along the way for comparison.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alcaid on April 10, 2013, 03:47:21 am
Looks like there would be nothing but benefits from running a smaller turbine housing A/R

A smaller turbo to help spool it up would also work ;) If you are afraid of back pressure, just run it sequential and bypass the small turbo when back pressure rises ;)

Do you have any wheel dimensions on the S2B? Most likely you have a 76/47mm compressor wheel and a 74/58mm turbine wheel. Do you have a .85 or .76 A/R turbine housing?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: carrizog60 on April 10, 2013, 08:12:44 am
I think lag will be ok with the quick spool valve and than it is nearly a twin turbo setup, but time will tell us.

Best Regards


where can i find more info on quick spool valve?never heard...
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on April 10, 2013, 10:36:38 am
google it!  ;D

it is for using with a split scroll turbine housing on a non split exhaust manifold, the valve cuts off flow to one side of the turbine housing which cuts the a/r of the housing in half making for faster spool up, then as boost comes on and more flow is needed the valve opens and doubles the a/r making for more flow on the exhaust side.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on April 10, 2013, 11:23:13 am
here is a good thread

http://www.gtrpwr.com/showthread.php?t=1665 (http://www.gtrpwr.com/showthread.php?t=1665)
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 10, 2013, 01:29:05 pm
Hi,

@Alcaid

It would like to run sequential turbo, but for me it is not as easy to manufacture and control a setup with two turbos, as it sounds in your post. Theres is also not so many space in a golf mk2 engine bay and i think packaging could be a real task by putting sequential turbos on the engine. I only put this turbo on the engine, because i want to know what happens and how it feels to have such a big turbine, the compressors from my previous S2a and S100 turbos was both absolute captable for all circumstances i could create with the AAZ engine.

I see clear benfits from the big turbine, because the measured 170 hp should be the most healthy 170 hp ever extracted from a AAZ. Unfortunately my egt sensor is not installed, because i did not want to drill a hole in the expensive manifold,  and before it was installed in the T3 / T25 adapter, but i am sure that the egt was in a good range during the hole dyno run, which was not the case with the smaller turbines und higher boost pressures.

As written before, i suspect not so bad spool with the qsv but with still good top end power, in fact it is than quite similar to sequential turbos.

Best Regards
Alleslowbuged 
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: carrizog60 on April 10, 2013, 05:48:10 pm
here is a good thread

http://www.gtrpwr.com/showthread.php?t=1665 (http://www.gtrpwr.com/showthread.php?t=1665)

neat idea!
thanks for the link  ;)
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alcaid on April 11, 2013, 02:31:35 am
Theres is also not so many space in a golf mk2 engine bay and i think packaging could be a real task by putting sequential turbos on the engine.

I know all about that, I am in the progress of tossing it all into a mk1, it is giving me a headache and grey hairs...

As written before, i suspect not so bad spool with the qsv but with still good top end power, in fact it is than quite similar to sequential turbos.

Not even close to a sequential setup! No matter how small A/R on your turbine housing you still need to spool up a turbo with big and heavy internals. Will never beat the spool up of a way smaller turbo, and at the same time the small turbo is helping to spool the big one as it is pulling air through it meaning you spool the big turbo on both wheels instead of just on the turbine.

Anyway, I really appreciate your postings on this forum, your experiments and your way of documenting the results and sharing with us is really appreciated! :)
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 11, 2013, 03:31:52 am
Hi,

@Alcaid
I agree on all points, i just wanted to state out that i was aware of the result of the big turbine housing and the very high inertia of the turbo rotor, before i install the S2B, but nevertheless wanted to see what will be the power output and how the engine will feel through the complete power band.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 11, 2013, 06:08:43 pm
Hi,

here are two crappy handy vids from today:

back view (smoke check):
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/th_Golf_2_AAZ-S2B_nach_hinten_20130411_zpsa1da4dfc.jpg) (http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf_2_AAZ-S2B_nach_hinten_20130411_zpsa1da4dfc.mp4)

front view:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/th_Golf_2_AAZ-S2B_Tacho_20130411_zpsa5c7080e.jpg) (http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf_2_AAZ-S2B_Tacho_20130411_zpsa5c7080e.mp4)

I also carry out a new G-tech run today and ended up with 15,44s @ 149,75 km/h for the 1/4 mile. I still analyse the data, so more to that topic tomorrow. What is very starnge is, that i get up to 1,5 bar boost pressure in second gear and full 2,0 bar in all higher gears. I suspect that the turbo needs to "run in" and get loose in the bearings, but did never heard that before for a turbo charger. I mean that a sleeve bearings, they normaly should perform right out of the box, but pherhaps the clearance is really really tight in factory condition, which would mean that i should not have stressed the turbo so high for a while.

Best Reagrds
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on June 04, 2013, 10:18:34 am
any updates from deutschland?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on June 04, 2013, 02:45:18 pm
Hi,

yes some strange things goes on, but later on that.

First my QSV arrives last week (good), i was willing to install it last weekend, but than i get a cold and also could not find a shop for heat resistance bolts to fit the turbo with the quick spool valve. Than i have done some maintenance, like proper fitting the rear bumper after some f..king stupid idiot crash into the rear bumber (during the car was parked on the side of a street) and did not stop to tell me,  polish the car to get i red again, readjust the rear hand brake, put some oil in it, put some water in it and so on. It is sheduled to install the QSV next weekend, so i hope to come back with something interesting than.

Now we come to strange thing, as i write earlier the big turbo has increased the max. possible boost level from a bit more than 1,0 bar to over 2,0 bar after the first week of driving. Now i want to know what is the max. boost level so i ordered a 3,0 bar (~45 psi) boost gauge from VDO and installed it some minutes ago, but instead showing me how far the max. boost level is above two bar (~30 psi) it shows only a bit more than 1,0 bar (15 psi) as max. boost level. I have to say that i only accelerate hard in second and third gear, so i assume to get it near 1,5 bar in fourth and fifth gear but way of what the other boost gauge shows. Now it's gets even more complicated, the first boost gauge (range of 1,5 bar) i have used has shown a lot less boost than the second one (range of 2,0 bar) (you can read this a few pages ago), but because the first one was a 10€ cheap no name thing from ebay i was sure the 40€ brand second gauge would be the correct one. Now you could argue the first one was correct as the new VDO is either, but this would mean the last dyno run with 1,0 bar from the second would have been conducted by far less than 1,0 bar wich would be not in line with the measured power figures.  ??? ??? ??? ??? ??? ???

The only thing i can imagine in the moment is, that the first gauge was bull***, the second was correct up to the point the boost level of the S2B turbo increases without a reason and also the VDO is correct now. But the question mark there is, why should a boost gauge start over night to show nearly twice the boost as bevore? What would be in line with that, is the fact that my 1/4 mile time with 1,0 bar at the gauge (right after the dyno run) was nearly identical with the one with more than 2,0 bar at the gauge.

Here are all analysed G-Tech runs:
(purple und orange are two runs from februar 2012 with >2,0 bar, light blue is actual with S2B turbo >2,0 bar (second gauage), green is actual performance curve in second gear)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-Leistung-alle-1_20130513_zps7b98389b.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/Golf-Leistung-alle-1_20130513_zps7b98389b.jpg.html)    

here is direct comparement between 2012 (S100) and 2013 (S2B):
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-Leistung-2012-2013-1_20130513_zps8eab98b2.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/Golf-Leistung-2012-2013-1_20130513_zps8eab98b2.jpg.html)

and here G vs. speed:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-g-2012-2013-1_20130604_zps9caf776d.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/Golf-g-2012-2013-1_20130604_zps9caf776d.jpg.html)

and here is g vs. time (stock g-tech plot), which is useless because it shows you higher g's at higher time when you was slow up to there and your speed is therefore also slower
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-g-vs-Zeit-2012-2013-1_20130513_zps353a5eab.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/Golf-g-vs-Zeit-2012-2013-1_20130513_zps353a5eab.jpg.html)

here is a comparement beween the engine load from dyno run and g-tech data, corrected for drag and drive train losses:
(the dotted ine is g-tech, the other is dyno run)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-Leistung_Messung-vs-G-Tech_20130513_zpsb85d797b.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/Golf-Leistung_Messung-vs-G-Tech_20130513_zpsb85d797b.jpg.html)

and last but not least two pictures of the QSV and an actual one from the golf:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0445_zps1da7dbc2.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0445_zps1da7dbc2.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0444_zpsfd17f3f0.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0444_zpsfd17f3f0.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0448_zpsc5ccf2b8.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0448_zpsc5ccf2b8.jpg.html)



  







  

    
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on June 04, 2013, 06:18:37 pm
Very nice to get an update! Good luck with your qsv

Ill have to read over the last page so i can understand what youre saying about the gauge issue,  its alot to keep track of!
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on June 05, 2013, 01:41:21 am
Hi,

sorry it is difficult for me to explain in english without using 1000 words, here is a short try:

First boost gauge has a range of 1,5 bar.
Second boost gauge has a range of 2,0 bar and has shown much higher boost as the first gauge under the same conditions. At that time i was sure the first gauge was wrong, because it was very cheap.
Third boost gauge has a range of 3,0 bar and now shows much lower values than the second gauge under the same conditions.

I hope that make it a bit easier to understand.

Best Regards
Alleslowbuged
 
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on June 05, 2013, 08:02:23 am
Hi,

sorry it is difficult for me to explain in english without using 1000 words, here is a short try:

First boost gauge has a range of 1,5 bar.
Second boost gauge has a range of 2,0 bar and has shown much higher boost as the first gauge under the same conditions. At that time i was sure the first gauge was wrong, because it was very cheap.
Third boost gauge has a range of 3,0 bar and now shows much lower values than the second gauge under the same conditions.

I hope that make it a bit easier to understand.

Best Regards
Alleslowbuged
 

your english is very good actually, and i understood all of what u repeated, i meant i didn't quite understand the context of it as far as whether or not you were actually making more power at much lower boost with the larger turbo or not.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: mtrans on June 05, 2013, 02:44:47 pm
Hard on English too but,
You know most instruments have better reading in last 1/3 of range.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on June 05, 2013, 03:08:03 pm
Hi,

i know that, but we speak here 2,0 bar to 1,0 bar this is 100% diffrence, or would be 30% uncertainty for the 3 bar gauge. Normal uncertainty for a pressure gauge is 1%, which would mean 0,02 bar for the 2,0 bar gauge and 0,03 bar for the 3,0 bar gauge, so the issue is not uncertainty. I think i will make a comaprison with all 3 gauges at the same pressure line and will check what the show.

Best regards 
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on June 05, 2013, 07:13:24 pm
For my job i work on pft testing and life support equipment if u waste a bunch of money on shipping i can certify all your gauges haha!
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on June 08, 2013, 10:50:43 am
Hi,

i have some news on the gauge issue. Today i have checked all my boost gauges with my compressor, here are the results:


First Test:
old gauge (from my old mk1)              0,60 bar
first gauge (cheap from ebay)             0,58 bar
second gauge                                  0,98 bar  (this is the one i have used the last month)
third gauage (VDO)                           0,55 bar

Second Test:
old gauge (from my old mk1)               1,17 bar
first gauge (cheap from ebay)             1,09 bar
second gauge                                  1,70 bar  (this is the one i have used the last month)
third gauage (VDO)                           1,10 bar

I think it is easily to see that my last gauge (second one) is not working properly and shows way to high boost pressure. This also means that the last dyno run with 170 hp was maximum with 1,0 bar boost, expected to be even a bit lower. What i realy like on this finding is, that this means that i can dismount the complete wastegate and do not have to bother with a new dump pipe. Second benefit is that i can use the wastegate flange to fit a blind flange, which will carry my egt sensor, so i do not have to drill a hole in the rather expensive exhaust manifold.

Unfortunatelly i did not have had enough time to install the QSV today, but i testet the opening pressure and was pretty happy with is. I will start to open at approximate 0,4 bar, at 0,5 bar it tis still nearly close and at aprroximate 1,0 bar it is fully open. This means that i do not need a boost controller for the opening sequence, because that are nearly exact the values i want to have. I think it would be even more effective to start openeing a bit later, but i worry to get a surge problem in that case.

Best Regards
Alleslowbuged

P.S. Pherhaps i will be able to getting a papmahl GTD II exhaust system, which would mean best diesel sound on planet earth  ;D ;D
  
  
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on June 08, 2013, 01:29:49 pm
ok time for 2 bar!!!!!

but in all seriousness the large turbo is very cool!  it looks like you can easily adjust the qsv to add more preload to it so it doesn't open as soon,  maybe tighten it until you get some surge and then back it off a hair and enjoy much faster boost.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on June 09, 2013, 06:00:42 pm
Hi,

here are two pics, one from the new boost gauge and one from the car (just because i polished it bit last week)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0470_zpscacca2a2.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0470_zpscacca2a2.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0473_zps8895b914.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0473_zps8895b914.jpg.html)

We have make a bigger tour today, first with the Golf and afterwards again with a E36 325 TDS from a friend, with both was great fun. It did not look all the time at the gauge, but i see serveral times approximate 1,2 bar and my friend say that we hit 1,7 bar once, when i accelerate through second, third and part off fourth gear in a straight line. What i also reconize today is , that the car feels allready strong with only 0,2-0,3 bar of boost, which will mean nearly nothing on a stock AAZ.

Best Regards 
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: carrizog60 on June 10, 2013, 12:42:25 pm
engines love flow,not pressure ;D
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on June 13, 2013, 05:15:51 pm
Hi,

i take a day vacation today and after serveral hours in my garage the quick spool valves is installed. I will come back with details tomorrow.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: carrizog60 on June 13, 2013, 05:32:43 pm
waiting for news then
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alcaid on June 13, 2013, 06:36:21 pm
Results? ;)
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on June 14, 2013, 03:29:01 am
Hi,

here some pics from the installation:

car prepared
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0459_zpsec59b973.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0459_zpsec59b973.jpg.html)

engine bay before:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0460_zps43eb5399.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0460_zps43eb5399.jpg.html)

distance between turbo and firewall - before QSV
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0461_zps677912bd.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0461_zps677912bd.jpg.html)

how a compressor housing looks, if the blow-by goes into a catch tank, instead of the air intake
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0462_zps866d92d3.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0462_zps866d92d3.jpg.html)

Turbo out and fitting test with QSV
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0464_zps309f05ef.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0464_zps309f05ef.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0465_zps36e7710e.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0465_zps36e7710e.jpg.html)

The port with the flap in the QSV is bigger than the usual T3 divited flange port, so that the resultant port size with open flap is more or less the same size as the stock port size. But this means, that there is likely an intereference between the flap and/or the turbo and manifold flange:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0470_zps942ae15c.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0470_zps942ae15c.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0469_zps4fe4a39d.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0469_zps4fe4a39d.jpg.html)

So i marked the amount that has to be removed and grind it of
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0471_zps1221fa39.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0471_zps1221fa39.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0474_zps80fc9e27.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0474_zps80fc9e27.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0475_zps70529cc6.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0475_zps70529cc6.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0476_zps10a0d831.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0476_zps10a0d831.jpg.html)

I have to do the same job on the manifold flange, but there i only have to cut the edges a little bit.

As i wrote, i also dismount the wastegate and intalled a blind flange with my temperature probe instead

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0468_zps9048a629.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0468_zps9048a629.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0473_zps1022d18c.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0473_zps1022d18c.jpg.html)

Here the turbo sits again, was a hard pice of work to bring in the first bolt with the three pices (turbo, qsv and gasket), at least because the turbo is a bit heavy
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0480_zps9b3b5b31.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0480_zps9b3b5b31.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0477_zpsfe9d1379.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0477_zpsfe9d1379.jpg.html)

Because the wastegate has sit below the turbo and the actuator does also, the engine bay looks the same as before, the only difference is that the gab between the turbo and the firewall has shrunken.

Yesterday it heavily rained here, so i did not make proper test runs, but it is obvious that the midrange torque and power figures has been boosted through the QSV. The boost response is now near to the S2A / S100 turbos i have had installed before (as far as i remember). I tried to conducted a 1/4 mile run with the g-tech, but was not able to find traction in first and second gear (even with serveral throttle lifts in second), but i conducted a g-tech dyno run in third.

here are the power figures:
orange is S2A 190 hp dyno run, red is S2B dyno run, red dotted is S2B g-tech dyno run in third and blue is S2B + QSV g-tech dyno run
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-2_GTD_AAZ_S2B-QSV_Vergleich_Leistung_20130613_zpsbf132e6d.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/Golf-2_GTD_AAZ_S2B-QSV_Vergleich_Leistung_20130613_zpsbf132e6d.jpg.html)

here are the torque figures:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-2_GTD_AAZ_S2B-QSV_Vergleich_Drehmoment_20130613_zpsf222ce25.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/Golf-2_GTD_AAZ_S2B-QSV_Vergleich_Drehmoment_20130613_zpsf222ce25.jpg.html)

Even if the peak power is nearly unchanged, it could be seen the midrange power (~3700 rpm) has increased by not less than 40 hp and midrange torque by aproximate 70 Nm.

Here you can see, that the third gear peak power is highes i have ever measured with the g-tech in third gear
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-2_GTD_AAZ_S2B-QSV_Leistung-vs-Geschwinfigkeit_20130613_zps6e92e76f.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/Golf-2_GTD_AAZ_S2B-QSV_Leistung-vs-Geschwinfigkeit_20130613_zps6e92e76f.jpg.html)

which is in line with the g-measurement
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-2_GTD_AAZ_S2B-QSV_Gs-vs-Geschwinfigkeit_20130613_zps158f6b15.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/Golf-2_GTD_AAZ_S2B-QSV_Gs-vs-Geschwinfigkeit_20130613_zps158f6b15.jpg.html)

But the comparement is a bit unfair, because i rev up all the way in third and therefore build up boost for a longer time, than accelerate in second and than shift (boost pause) and wait again for boost third. So we will see real comparement figures with the next dry 1/4 run.

Nevertheless i feel comfortable to state, that i think that the qsv was a good achievement.

Best Regards
   
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: carrizog60 on June 14, 2013, 06:06:42 pm
that is good news then!
how is controlled the vacuum can of the qsv?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on June 14, 2013, 06:44:20 pm
Hi,

the actuator is boost controlled not vacuum and straight connected with the inlet manifold. It started to open 0,4 bar and is fully open at approximate 1,0 bar. I have a manual boost controller installed, but did not use it for the moment. I could increase the opening pressure and increase the midrange torque further, but for me it is actual enough. I make a 1/4 mile g-tech run today and achive a 14,8s, which is the best ever measured time for me (for all cars), data analysis from the g-tech shows also higher g's over nearly the hole rev band in comparison with the 190 hp run from 2012.

So for me it is clear that this QSV makes what it is design for, in fact it is the same as a twin/compount turbo setup, only with much easier packaging. It's a real shame that these things are so expensive, i mean for the moment it feels worth the money, but if you have it your hands it seems like 100-150% overpriced.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on June 15, 2013, 08:37:27 am
Hi,

here are the updated diagrams with the 1/4 run instead of the dyno run

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-2_GTD_AAZ_S2B-QSV-2_Leistung-vs-Geschwinfigkeit_20130614_zpsaf396421.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/Golf-2_GTD_AAZ_S2B-QSV-2_Leistung-vs-Geschwinfigkeit_20130614_zpsaf396421.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Golf-2_GTD_AAZ_S2B-QSV-2_Gs-vs-Geschwinfigkeit_20130614_zps78ef88cd.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/Golf-2_GTD_AAZ_S2B-QSV-2_Gs-vs-Geschwinfigkeit_20130614_zps78ef88cd.jpg.html)

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on June 16, 2013, 10:47:32 am
Ok time for more boost
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on June 16, 2013, 02:16:37 pm
also, out of my own curiousity do you know the inducer and exducer sizes of the compressor wheel?


Also does this give you the desire to install a similar setup on to your bavarian td??
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on June 18, 2013, 06:16:50 pm
Hi,

i am sure that i have measured the compressor wheel dimensions in 2008 or 2009, but i can't find my recordings. I have mesured the turbine wheel dimension during the grinding of the turbine casing, but forget my note in my garage, but will bring that data with one of my next posts. I was also thinking of open the compressor housing and measure the compressor wheel again, but the retainer, who fixed holds the housing in place, is a real pitty to dismount and mount, it tooks me 30 minutes or so last time and i have had to buy a better caliper before, because with my old caliper i have had no chance.

The answer to your second question is clearly yes, for me the qsv + very big turbo is the best setup in the moment. The manifold of the BMW's are divided, so if i want to install a qsv i have to remove the spilt wall first. It is also not so easy to package a external wastegate in the BMW's, that why i still use the stock turbo there. I am sure that also my S2A without a QSV would be an improvement over the stock turbo, but also there the wastegate is a problem for me. The old e28 BMW, will not see a new big update, because is will be an oldtimer soon and the engine has a bit wear now, but i have bought a 1996 E36 325 TDS Limo, which is my next project car (after the Golf), it is sitting in my shop in the moment and waits for a ported head, performance pump, camshaft, lsd, bilstein suspension. Before i tested the qsv in the Golf was scheduling to stay with the stock manifold (triangle shape) and stock turbo, but now i am thinking of using the S2B and the QSV in the e36 together with a manifold from a E28 524 TD, but i am still thinking.

Here are some pics of the cars (i was also thinking of starting a built thread here, but was to lazy, because i have allready started a german built thread)
(http://i702.photobucket.com/albums/ww24/euro-styler/E36%20325TDS%20Limo%20manual/DSC_0469_zps4e267455.jpg) (http://s702.photobucket.com/user/euro-styler/media/E36%20325TDS%20Limo%20manual/DSC_0469_zps4e267455.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/E36%20325TDS%20Limo%20manual/DSC_0474_zps847d6c44.jpg) (http://s702.photobucket.com/user/euro-styler/media/E36%20325TDS%20Limo%20manual/DSC_0474_zps847d6c44.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/E36%20325TDS%20Limo%20manual/DSC_0481_zps37d86189.jpg) (http://s702.photobucket.com/user/euro-styler/media/E36%20325TDS%20Limo%20manual/DSC_0481_zps37d86189.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/E36%20325TDS%20Limo%20manual/DSC_0479_zps1e69c486.jpg) (http://s702.photobucket.com/user/euro-styler/media/E36%20325TDS%20Limo%20manual/DSC_0479_zps1e69c486.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/E36%20325TDS%20Limo%20manual/DSC_0484_zps7231c1c1.jpg) (http://s702.photobucket.com/user/euro-styler/media/E36%20325TDS%20Limo%20manual/DSC_0484_zps7231c1c1.jpg.html)

new rims
(http://i702.photobucket.com/albums/ww24/euro-styler/E36%20325TDS%20Limo%20manual/IMG-20130516-WA0000_zps12c6787b.jpg) (http://s702.photobucket.com/user/euro-styler/media/E36%20325TDS%20Limo%20manual/IMG-20130516-WA0000_zps12c6787b.jpg.html)

head:
(http://i702.photobucket.com/albums/ww24/euro-styler/E36%20325TDS%20Limo%20manual/DSC_0433_zps40903771.jpg) (http://s702.photobucket.com/user/euro-styler/media/E36%20325TDS%20Limo%20manual/DSC_0433_zps40903771.jpg.html)

interesting shape of the piston head, i was wonder if this could be an update for the M21 engine
(http://i702.photobucket.com/albums/ww24/euro-styler/E36%20325TDS%20Limo%20manual/DSC_0437_zpsc5e35835.jpg) (http://s702.photobucket.com/user/euro-styler/media/E36%20325TDS%20Limo%20manual/DSC_0437_zpsc5e35835.jpg.html) 

head cleaned
(http://i702.photobucket.com/albums/ww24/euro-styler/E36%20325TDS%20Limo%20manual/DSC_0450_zpsc3ce0c8d.jpg) (http://s702.photobucket.com/user/euro-styler/media/E36%20325TDS%20Limo%20manual/DSC_0450_zpsc3ce0c8d.jpg.html)

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on June 19, 2013, 07:29:02 am
wow look at the space between those valves, plenty of room for upgrading  :o
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alcaid on June 19, 2013, 02:10:48 pm
Space between valves is one thing but distance from valves to bore diameter doesn't look like it gives room for any bigger valves than a standard oversize (+1mm?)
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Gizmoman on June 19, 2013, 09:15:21 pm
Space between valves is one thing but distance from valves to bore diameter doesn't look like it gives room for any bigger valves than a standard oversize (+1mm?)
That space is possibly why it's not cracked like my previous, and most other used AAZ heads I have seen. Somebody finally figured out it cracks when they are too close ;D
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on June 20, 2013, 12:35:22 pm
Hi,

today i get my famous Papmahl GTD II exhaust system (the GTD I system has have the best diesel sound ever) and the big front mounted Papmahl intercooler (similar to merc sprinter intercooler) but better ports for a MK 2.

I don't know when i will install the front mounted intercoller, because i have to change the position of the oil cooler for that. But if it work without bigger problems i will try to install the exhaust system this weekend.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: carrizog60 on June 20, 2013, 06:06:37 pm
wont a simple and cheaper straight pipe be better for performance?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on June 21, 2013, 02:49:24 am
Hi,

the Papmahl mufflers has no restrictions (as also my current muffleres has no), they are "straigth pipes" make of perforated sheets with a bit insulating wool around, so from a performance point of view there is no difference between a striaght pipe and this type of mufflers.

Best Regards
Alleslowbuged 
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on August 05, 2013, 05:56:35 pm
Hi,

i have had a very hard overheating situation three weeks ago, which causes a hard leaking headgasket ( 2 ltr. water per 25 km without load, without boost) , but yesterday i managed to do my first official sub 15,0 second 1/4 mile run (the same head, the same crack, the same headgasket). My best run was a 14,87 s.

I will post some more details the comming days.

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on August 05, 2013, 06:24:15 pm
yay an update from deutschland!!!

good luck with ur crack and hg issues...
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: carrizog60 on August 09, 2013, 06:08:58 pm
time to source a new head and go more gentle on the dremel  ;D

nice time btw,now if you could have more boost out of it...


dont want to highjack but on a side note in portugal a tdi managed to be on the 10´s.

dont know for you guys but idi or tdi is a 1.9 diesel and for me thats impressive!
http://www.youtube.com/watch?feature=player_embedded&v=DihwmYVw9hs
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: CrazyAndy on August 09, 2013, 07:53:46 pm
Sorry to hear of your water jacket failure in your modified head.  I hope you are able to fix it, as this is one of my favorite AAZ-engined cars on here.  Glad to hear you have beaten your previous 15 second attempts. 
IMHO I think you should run the front mount intercooler; that way you are not stuck scavenging air from around the bottom of the car near the hot asphalt, and can pul air from a larger area behind the radiator grille.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Rising on August 10, 2013, 11:59:09 am
A golf diesel in the 14's! This is outstanding! Congratulations and sorry for your loss!

Now if i can get mine out of the 20s!  ::)
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on August 10, 2013, 03:55:12 pm
u can get to 16's easy, my old 1.6td with k24 would do low 16's only mods was increased boost and fueling, cone filter and exhaust.  didn't even have governor mod.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on August 10, 2013, 05:05:53 pm
Hi,

you are right, 16,x s and also high 15,x s are easy, but to get into the 14,x s took me 3 Years. Tomorrow is a 1/8 mile race were i will start also, but unfortunatelly my three days of full work in my garage did not look like pay of anyting.

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0534_zps8085e8a6.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0534_zps8085e8a6.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0535_zps9d8e61e2.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0535_zps9d8e61e2.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0536_zps2b97cfcb.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0536_zps2b97cfcb.jpg.html)

I took of the gearbox to change the sport clutch to a sachs race engineering sinter metal clutch:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0538_zps902a6af5.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0538_zps902a6af5.jpg.html)

I also bought some stuff to soften my sliks, but it came to late to use it for tomorrow.
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0542_zpsedb2a0d8.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0542_zpsedb2a0d8.jpg.html)

I also change the intercooler to a front mounted cooler, this was my selection (Sprinter, Papmahl, Volvo):
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0546_zps149c574e.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0546_zps149c574e.jpg.html)

Therefore the oil cooler need a new place:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0547_zpsf022aab5.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0547_zpsf022aab5.jpg.html)

I choose the papmahl, which is specialy for the golf mk II, but have to grind a bit of the front:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0550_zpsd6b04bb7.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0550_zpsd6b04bb7.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0551_zps47907275.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0551_zps47907275.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0559_zps3379a657.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0559_zps3379a657.jpg.html)

Today i have also installed a water methanol injection, which i have used in my BMW E28 a couple of years ago. Because it was late today when i finish my work, i forgot to make picture from the intercooler pipes and the waes system. Anyhow my three test drives today was all slower than last week, i did not change anything on the injection pump or the turbo, but the turbo spools much worse than last week and there is a lot of smoke with the same pump setup. The only different is a new fuel filter, but i can not image how this could make my car slower. In the highest rpm range (4800 - max.) i think it is nearly as quick as before and low end grunt is also the same, but mitrange is much worse than before and i have no idea why? 
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: theman53 on August 10, 2013, 05:37:37 pm
Must be the IC? I suppose the filter could be restrictive but with black smoke you would think it is flowing just fine.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on August 10, 2013, 06:00:04 pm
Hi,

yes after sitting here for a while i would agree, must be the intercooler, but why? The Intercooler is approximate twice as big as the stock VW intercooler, it should be less restrictive and not more restrictive, thats the reason why i installed it. Do you have a good suggestion, how to test the intercoller in regard of flow capability?

Best Regards
 
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: 8v-of-fury on August 10, 2013, 06:42:42 pm
Could it not just be extreme lag?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: theman53 on August 10, 2013, 09:24:45 pm
Well the issue probably is too much flow. The air might not be getting cooled in the bigger units as it flows straight through before getting colder. I went from a 28x7.5x2.5 to a 28x5.5x2 *or so* and have less EGT issue than I did before on the last engine...but this engine/turbo setup is wildly different so it is apples and oranges. I do think the slightly smaller intercooler helped spool and cooling function. I honestly don't know what it is other than those guesses.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: 8v-of-fury on August 10, 2013, 09:34:49 pm
It is a tough one, because we are not scientists.. WE have no idea LOL.

Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: 410 on August 10, 2013, 09:38:34 pm
Do you have a boost leak maybe?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on August 11, 2013, 05:42:03 pm
Hi,

just short notice, because it is very late in Germany and i just write it all down (4x A4 paper) in german, the day was horrible, the car break down serveral times (no overheating issue) and the best time was a 9,7s (without intercooler) after three 10,5s - 10,7s runs.

The only good think is, that i could drive home without help and the car maintan it's" zero total break down" state. I think that the problem is caused by surge, but could also be due to piping forces from the intercooler pipes, i do not know. Everthing else later, here just two pictures:

How it look this morning (without the hole) and this evening (with the hole, which was no serious issue)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0563_zps6d5056cb.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0563_zps6d5056cb.jpg.html)

This how it (nearly) looks, during my best run (with WAES)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0560_zpsc7ac0b8f.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0560_zpsc7ac0b8f.jpg.html)



and how the compressor housing is orientated now:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0562_zps222b9deb.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0562_zps222b9deb.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0561_zps168fface.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0561_zps168fface.jpg.html)

and what is look this morning (i did not rotate it):
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0477_zpsfe9d1379.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0477_zpsfe9d1379.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0461_zps677912bd.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0461_zps677912bd.jpg.html)

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: carrizog60 on August 12, 2013, 05:05:57 pm
you didnt rotate it?
loose bolts then?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on August 12, 2013, 05:18:17 pm
Hi,

no i did not rotate it. The compressor housing is fixed with a retaining ring, but it is so stiff, that it is not possible to rotate it by hand, when the retaining ring is not loose.

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: CrazyAndy on August 12, 2013, 09:20:23 pm
Perhaps your seal around the compressor housing is leaking, forcing the housing's retaining ring to raise out of it's slot slightly, allowing the compressor housing to rotate.  I think maybe your lag concern is caused between that and the larger intercooler, although more of the latter.  Remember, the larger the intercooler, the more volume of air is needed to be compressed in it, hindering the building of boost.  Have you considered air-to-water intercooling?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: theman53 on August 12, 2013, 09:25:11 pm
If your compressor is rotating that could be all your lag issues. Lord Verminaard on here had the same issue and as soon as he got it tight no more lag issues.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on August 13, 2013, 04:41:57 pm
Hi,

yeah after thinking a bit more about it, i also think that the intercooling pipes causes my problem, by creating too high forces at the compressor housing. At 1,5 barg these stupid axial compensators produce approximate 290 N (~29 kg) thrust and i know think that this causes either a slighly bend of the housing, which prevent the shaft from proper spooling or causes a leak, whichs both end up with non optimal performance. This would also explain, why the car has had normal acceleration during no and low boost (up to app. 0,5 bar) and then stops to spool further for app. 2000-3000 rpm, before somewere above 5000 rpm it starts to pull again, when the turbine has realy high power.

We will see in the next weeks, no i have to fixe my cluth issues as first step and then i can look for power production again.

Best Regards
Alleslowbuged

P.S.

i just see, that i did not have mentioned that first my clutch bowden cable fails and now the internal linkage to open the clutch is bend, so that i can not open the clutch anymore
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Rising on August 17, 2013, 02:07:21 pm
Hi,

you are right, 16,x s and also high 15,x s are easy, but to get into the 14,x s took me 3 Years. Tomorrow is a 1/8 mile race were i will start also, but unfortunatelly my three days of full work in my garage did not look like pay of anyting.


Oh sure you say that but then I see 81 vw's signature that says "81 vw caddy converted from 1.7 gasser to 1.6 NA. Diesel W/ FF 5 speed.
1.6 TD intake and exhaust w/k14 turbo,intercooled, 2.5" straight pipe. NA. pump with govenor Mod and a 50 shot of nitrous!!!

Best 1/4 mile pass= 16.8 @ 85 mph"

I'm not sure i'd classify nitrous and the gov mod as EASY and he's barely out of the 17's!

Do you have a list somewhere of all your mods so that one might get some kind of idea how far down the rabbit hole one has to go to break into such fantastic times?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on August 18, 2013, 11:15:36 am
Maybe he needs a bigger turbo or to crank the fueling up?  Mine did low 16s with stock k24 25psi, increased fueling, stock cast dp into a 2" dp in a techtonics 2.25" exhaust.  And it had a cone filter instead of an air box.  In a mk1 jetta coupe with basically no options, no ac or any of that.  Had no intercooler or anything
Title: Re: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Rising on August 19, 2013, 01:37:40 pm
I wonder what the weight difference between a caddy and a jetta coupe is. That could account for a couple tenths. I'm hoping my stripped out rabbit L should be pretty light compared to like the golf 2 this thread is about. Could account for a tenth or two. I bet tire size and type effects light fwd diesel cars a lot as well.

Alleslowbuged: What other factors should one consider when going for e/t? Have you determined how much grip is effective etc. Thanks!

Sorry to thread jack! Can't wait to see what this thing runs with a proper clutch!

Sent from my ADR6400L using Tapatalk 2
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on February 08, 2014, 05:32:28 pm
Hi,

long time ago since my last post.

I get the clutch issue fixed but did not found a solution for the strange power behaviour. I change the support point for the clutch cable and use an original self adjusting VW clutch cable, which works until now. But in summarize the sinter metall clutch makes the car worse and not better. With the clutch it was not longer good to use as daily driver and than also one or two glow plugs stoped working, so the car starts very very bad. With all the issues (power behavior, clutch, start issue), there was a point in Oktober last year, where i not like the car very much, bough a very cheap 1992 BMW 525 TDS as new daily driver and parked the car in my garage (unregistered).

Before that i have build a better intercoller pipe setup:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0598_zps54206071.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0598_zps54206071.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0599_zpsb383fb31.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0599_zpsb383fb31.jpg.html)

Before i take the number plates off a make a last quick drive through my favorite roads and have to commit, that even with that problems that little car droves just fine (the strange power behavior only occurs during 1/4 mile runs, not during normal quick driving) and has had enough power to make me smile.

Since oktober the car has sitting in my garage and i did not know what to do with it, i though i will sell it, not sell it, sell it, not seel it (i think most of you will know these situations). And than short before christmas i build a performance pump for a VW caddy mk2 with the lasted eddition of the aaz engine (with electronical advange timing) and start to realy miss my golf.

(http://i702.photobucket.com/albums/ww24/euro-styler/ESP%20Umbau/Locke/DSC_0647_zps0337a58d.jpg) (http://s702.photobucket.com/user/euro-styler/media/ESP%20Umbau/Locke/DSC_0647_zps0337a58d.jpg.html)

The caddy get the perfromance camshaft here from the board, the stock lift plate (3,05 mm) and an Ø11mm plunger. The guy also add an HKS EVC4 boost controller, and swapp the gearbox to an long geared 02A with a Ø228er cluth (the stock cluth was hopeless) and a lighweight flywheel.

(http://i702.photobucket.com/albums/ww24/euro-styler/ESP%20Umbau/Locke/DSC_0648_zps82258d9a.jpg) (http://s702.photobucket.com/user/euro-styler/media/ESP%20Umbau/Locke/DSC_0648_zps82258d9a.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/ESP%20Umbau/Locke/DSC_0649_zps907fb59e.jpg) (http://s702.photobucket.com/user/euro-styler/media/ESP%20Umbau/Locke/DSC_0649_zps907fb59e.jpg.html)

The pump is absolute at the optimum point from the lift plate - plunger setup and i also think that that electronical controlled pump timing could be an improvement against the hydraulic timing control.

But back to my golf, after starting to think again about the golf i decided to get a new head done, because the other one still has that crack from porting. I will also swap the turbo again, the Switzer S2B will go in my E28 and the golf will get the S2A again, which was installed during that 190 hp dyno run. But i will swap that turbine housing to a bigger twincroll one with T3 flange instead T25 flange and i will keep the QSV, so i hope to get very quick response from the S2A combined with the ability of high bost levels with relative small backpressure.

The new head is allready ready cleaned, flattended, ported and poilsh. Still to do is, to pull the old head, get the valves out and to regrind the valve seats of the new head in accordance to the old valves in regard of the needed gap between the valve head and the piston.

Here is new head during the disassemble:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0703_zps5f9a6027.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0703_zps5f9a6027.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0704_zps6caf8136.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0704_zps6caf8136.jpg.html)

and this is how it looks now:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Bild_von_Bluforce_zpsf69dedfa.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/Bild_von_Bluforce_zpsf69dedfa.jpg.html)

Best Regards
Alleslowbuged

     

   
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: CrazyAndy on February 10, 2014, 06:37:50 pm
Glad to her you are renewing your interest in the golf project.  Hopefully your new choice of head and turbocharger will eliminate or at least reduce your boost drop-off concern.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on March 15, 2015, 04:31:23 pm
Hi,

first remove the dust.........

I have some goof news, from today:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0024_zps2kbt2yqg.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0024_zps2kbt2yqg.jpg.html)

I am a VIDEO, click me
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/th_MOV_0027_zps7xkwrivw.mp4) (http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/MOV_0027_zps7xkwrivw.mp4)

Always nice to hear, how dirty a good old diesel sounds without an exhaust system.

I still search for a supplier you machine my turbo adapter.

Best Regards
Alleslowbuged


Gruß Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: theman53 on March 16, 2015, 06:51:52 pm
what turbo adapter are you looking for?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: golftd412000 on March 22, 2015, 06:38:47 am
nice update
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on March 22, 2015, 05:47:42 pm
Hi,

here is a drawing of the adapter, if anybody can offer a good price for milling oder plasma cutting the adapter, i am willing to receive any offer. I can do without any of the shown tolerances and will make the fine fit, by myelf.

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Zeichnung-R04_20150322_zpsmngvfi1l.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/Zeichnung-R04_20150322_zpsmngvfi1l.jpg.html)

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: theman53 on March 22, 2015, 11:02:02 pm
http://www.mandrel-bends.com/catalog/flanges-gaskets-36/turbo-flanges-62/

???

Are you trying to do something more special or is the stuff they have there OK?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on March 24, 2015, 03:46:05 pm
Hi,

thanks for the link, but i need a flange, which gas holes are divided T25 flange on one side and divided T3 flange on the other side. Oudside and bolt holes are T3 stright through.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on August 14, 2015, 07:13:43 pm
Hi,

i get some work done the last weeks.

All this stuff have to go in the car, oneway or the other.

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0304_zpsecvgkt04.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0304_zpsecvgkt04.jpg.html)

Here are some detailed pics from my 3D printed T3 / T25 twinscroll adapter. The Adapter is as delivered, with no manual work done afterwards. 

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0305_zpsu06e7p2a.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0305_zpsu06e7p2a.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0306_zpsfyrnwxwc.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0306_zpsfyrnwxwc.jpg.html)

Here are some pics from the first Fitting.

seen with the flow, we have the manifold (T3-singe), QSV (T3-divided asymmetric), adapter (T3-divided asymmetric - T25-divided asymmetric) and than the Turbo exhaust casing (T25-divided symetric)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0307_zpsnarmn3om.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0307_zpsnarmn3om.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0309_zpsslraxuhe.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0309_zpsslraxuhe.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0310_zpsi7bn6yrs.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0310_zpsi7bn6yrs.jpg.html)

As seen on the Pictures, i use the T3 bolt circle and grinded the T25 flange to fit.

Here are two pics seen with the flow through the hole package (QSV open / QSV closed)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0311_zpslhjcztxk.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0311_zpslhjcztxk.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0313_zpsby5iwrtn.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0313_zpsby5iwrtn.jpg.html)

That was test Fitting, know in the car:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0319_zpsrfqjzdch.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0319_zpsrfqjzdch.jpg.html)

roughly put together;
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0320_zps9noq7fhc.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0320_zps9noq7fhc.jpg.html)

The fit is very tight on serveral places so i have to cut and grind a lot, to make it possible to put everthing togehter.

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0321_zpscuudbonj.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0321_zpscuudbonj.jpg.html)

I have welded the first exhaust pipe for serveral times to make it fit with different turbo setup's, so this time i fitted a v-band joint.

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0324_zpsi02kzrhp.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0324_zpsi02kzrhp.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0325_zpssyynlhr1.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0325_zpssyynlhr1.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0326_zpsbpuq0brb.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0326_zpsbpuq0brb.jpg.html)

Most things installed properly now, the exhaust is complete together.

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0327_zpsgusbxejj.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0327_zpsgusbxejj.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0328_zpslugy5s7a.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0328_zpslugy5s7a.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0329_zpsn3viufpq.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0329_zpsn3viufpq.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0332_zpsp0cydk2s.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0332_zpsp0cydk2s.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0335_zpsur5inl9g.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0335_zpsur5inl9g.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0337_zpsxbzvfr1l.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0337_zpsxbzvfr1l.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0339_zpsqakxkboo.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0339_zpsqakxkboo.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0340_zps65bukxzp.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0340_zps65bukxzp.jpg.html)

tam ta ta tam:   ... the car is driving after nearly two years

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0347_zpsoymcr4ou.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0347_zpsoymcr4ou.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0346_zpsqjse0qaj.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0346_zpsqjse0qaj.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0350_zpslfchb7sn.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0350_zpslfchb7sn.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0351_zpsrilunmxc.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0351_zpsrilunmxc.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0345_zps1wtnesea.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0345_zps1wtnesea.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0342_zps7veszork.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0342_zps7veszork.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0354_zpsgrxbvckj.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0354_zpsgrxbvckj.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0353_zpswx6j4ryy.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0353_zpswx6j4ryy.jpg.html)

A few things are still to do, but the main issues is to get new license plates.

Gruß Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: theman53 on August 15, 2015, 08:27:02 pm
cool, how does it run
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on August 16, 2015, 05:25:03 pm
Hi,

i only drive it a few meters up and down, because it is not registered, but it felt pretty good. I can not say anything in regard of real power, because the LDA was not active but spooling felt quite ok.

I assemble the rest today and drilled a hole for pressure measurement and boost supply in the compressor housing. I also put the fron bumber and the grill back on the car. After looking nearly two years at the car without the front bumber, i forgot how much i like the front look of the car with the modified front bumber and grill.

I have made some pics and will post them soon here.

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on August 18, 2015, 04:02:59 pm
Hi,

here are the Pictures from the weekend

compressor housing without / with pressure tap

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0362_zpsqxsh5bd1.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0362_zpsqxsh5bd1.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0363_zpsvw2qe1yi.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0363_zpsvw2qe1yi.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0368_zpso2xzp6ll.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0368_zpso2xzp6ll.jpg.html)


some pictures from the turbo rotor (quite different trim on the compressor and turbine wheel)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0364_zpsuxvmfpml.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0364_zpsuxvmfpml.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0365_zpsbpuoluhx.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0365_zpsbpuoluhx.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0366_zpsmzaikylz.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0366_zpsmzaikylz.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0367_zpsd2xre4is.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0367_zpsd2xre4is.jpg.html)

engine bay complete

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0385_zpspdb2iuvf.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0385_zpspdb2iuvf.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0387_zpsynoapgaj.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0387_zpsynoapgaj.jpg.html)

front bumper assembled

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0369_zpsygxtrx0l.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0369_zpsygxtrx0l.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0370_zpsylvszadd.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0370_zpsylvszadd.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0371_zps6kqbkd0q.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0371_zps6kqbkd0q.jpg.html)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0383_zpsojemd6ga.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0383_zpsojemd6ga.jpg.html)

best regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on August 21, 2015, 07:32:04 am
great to see this thing is still running, have you driven the new setup much yet?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Ian0391 on August 21, 2015, 12:36:23 pm
Are you using the inner lights as intakes?

Sent from my SM-G920W8 using Tapatalk

Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on December 31, 2015, 12:45:52 pm
Hi,

the inner "lights" are just for providing the water and oil cooler with fresh air, no air intake for the engine. But to be honest, there are mainly as they are because i like the look.

I tried to get 5-day licence plates today but the office did not have open because of new year - damm - i am really curious how the engine perform with the new setup. However i hope to find time again in the next weeks.

Best Regards and a happy new year
Alleslowbuged   
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on January 05, 2016, 04:53:14 pm
Hi,

just found this to threads from a guy in portugal with very nice golf mk2 and golf mk1 TDI conversion builts:

Golf 2
http://forums.tdiclub.com/showthread.php?t=275682

Golf 1
http://forums.tdiclub.com/showthread.php?t=383058

On the Mk1 build they have used a volvo v70 2,5 tdi intake manifold (5cylinder)  and have shortend it to 4 cylinder, as have tried to do with a VW Touareg 5 cylinder (one cylinder bank) intake manifold. It looks kike as this would be nearly a plug and play swap, after shorten the manifold.

I really like the design, length and the volume of my current manifold (also from a guy from portugal), but i dislike the manufacturing quality and i am afrait, that the paper thin stainless steel will crack and debris will destroy the engine.

So i have directly buy one of these V70 intake manifolds and will try to build a custom manifold.

here are pics of the mk1 build of the guy from portugal:
(http://i4.photobucket.com/albums/y118/n1troxx/DSC_65250001_zpsceb720c7.jpg) (http://s4.photobucket.com/user/n1troxx/media/DSC_65250001_zpsceb720c7.jpg.html)

(http://i4.photobucket.com/albums/y118/n1troxx/DSC_65540001_zps6a146716.jpg) (http://s4.photobucket.com/user/n1troxx/media/DSC_65540001_zps6a146716.jpg.html)

(http://i4.photobucket.com/albums/y118/n1troxx/DSC_65520001_zps8601ee7c.jpg) (http://s4.photobucket.com/user/n1troxx/media/DSC_65520001_zps8601ee7c.jpg.html)

Best Regards
Alleslowbuged

P.S.
Does anyone remember the online shop were you could buy components to build a proper intake manifold (e.g. conical pipes etc.)



Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on February 09, 2016, 06:09:11 pm
Hi,

i have started to work on the inlet manifold, but still a lot to do.

Anyhow the big news are, that te car is at a shop of a friend to pass the general inspection, so that i can get new nunber plates and drive it again on public roads.

I am really looking forward to see how the new turbo setup will work.
Best Regards
Clemens
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Ian0391 on February 09, 2016, 09:28:41 pm
Did you end up finding the site for manifold parts?

Sent from my SM-G920W8 using Tapatalk

Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on February 12, 2016, 02:32:12 pm
Hi,

no i did not find it yet. I can remeber the layout of the site and the pictures of the single parts (like conical pipe etc.) and the DIY Set to built two chamber manifolds, but i can not remember the name of the shop and can not find the link anymore. I think the shop was located in the states or in the uk, but i am not 100% sure.

We have had the inspection last wednesday, but failed to pass due to serveral point. The inspector said that i need a new front  subframe, due to corrosion. I can not remember that i have seen some serious corrosion there, but i was not there during the inspection, so pherhaps i was only not aware of this. There was some other minor points, but not worth mentioning.

Best Regards
Alleslowbuged 
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on February 16, 2016, 06:29:11 pm
Hi,

just bought a new (OE Part refurbished and new powder-coated) front sub frame for my Golf as the Inspector did not like my front dubframe any more.


(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/_20-1_zpsza8j6g0r.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/_20-1_zpsza8j6g0r.jpg.html)

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on February 16, 2016, 09:19:00 pm
lets see the old one once you get it out.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: deepgrooves74 on February 17, 2016, 03:46:15 pm

lets see the old one once you get it out.

X2

Let's see how bad it really was.


Sent from my iPhone using Tapatalk
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on February 27, 2016, 05:28:34 pm
Hi,

it's done. We have passed the inspection and will bring it back on the roads in the next two weeks. As written i am really curious how the new turbo setup will work. The shedule is to start with approximate 15 psi boost for some miles and than go back to 30 psi.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: carrizog60 on March 07, 2016, 04:14:20 pm
30psi from that big turbo is going to be fun lol
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on March 20, 2016, 07:36:49 pm
Hi,

its finally done, the car is back at home and has number plates and is street legal again. I have driven approximate 50 km this day, but fully without any fine tuning regarding the injektion pump and the turbo. Low down torque in "na" mode is quite perky and turbo spool seems to be also quite good. The overall power was a bit missing, but i did not know the boost pressure most of the time, because i did have had a leackage in the boost line to the gauge. After the boost gauge was working i know, why the power was ok but not overwhelming, the boost pressure was only 7-8 psi. i would say, for that it feels good.

The tires seems a bit tired from standing arounf for so long, i did get some wheel shaking at around 150 km/h, so i thing i have to look for a new set of tires soon, which is ok, as the thread is also quite thin.

So i am happy to have the car running again and have had some fun to drive in it, with hopefully still more to come.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on March 25, 2016, 05:58:29 pm
Hi,

i did make two small test drives this week, both with increased boost pressure. The first one was with aproximate 15 to 17 psi and was tempting for give it some more. The next one was done with 22 in second and up to around 25 psi in third. I can not really remember how it felt at last with the bigger S2B, but i would imagine that the top end is a bit more restricted as with the S2B.

The boost built up very linear up to 15 psi and then really quickly ramps up to maximum boost. The QSV opens actual at 7,5 psi, which is not detectable during driving. With the S2B i did have installed a manual boost controller in the QSV line to open it later at approximate 15 psi, which makes the turbo spools up much more rapitly as i remember. This is one of the next things i will do.

Otherwise i did make a g-tech "dyno run" in second gear, but all my old g-tech "dyno runs" was done in third gear, so i could not make a real comparison. I would imagine that the actual peak power is approximate 160 - 170 hp, but it seems that it is not quite as revy as i think it was before. I need to check the timing of the pump and i think i will go back to a full d=63,5 (2,5") exhaust system, actual i have only d=60 mm.

Best Regards
Alleslowbuged     
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on March 28, 2016, 07:40:41 am
cant wait to see some graphs you always document everything so well it makes for a great read, you truly are german haha
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 04, 2016, 04:06:35 pm
Hi,

unfortunately i have only a few good news and much more bad news, but one after the other:


1. Pictures (good)
I have make some nice pictures (at least i like them)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/schoumlnes-Bild-seite_zpsb2zmea5h.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/schoumlnes-Bild-seite_zpsb2zmea5h.jpg.html')

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/schoumlnes-Bild-seite-oben_zpsz2duoymv.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/schoumlnes-Bild-seite-oben_zpsz2duoymv.jpg.html')

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/schoumlnes-Bild-seite-oben-2_zpsupj03oab.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/schoumlnes-Bild-seite-oben-2_zpsupj03oab.jpg.html')

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/schoumlnes-Bild-seite-oben-3_zpsu9u0odeh.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/schoumlnes-Bild-seite-oben-3_zpsu9u0odeh.jpg.html')


2. intercooler pipe (good)
I have changed the pipe between the turbo and the intercooler, because the closed hood compressed it to much with the old layout.

before:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0939_zpsbaatwlpw.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0939_zpsbaatwlpw.jpg.html')

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0943_zpskjjg1bov.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0943_zpskjjg1bov.jpg.html')

after:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0951_zpsgrybz5yr.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0951_zpsgrybz5yr.jpg.html')

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0950_zpsmyqszguz.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0950_zpsmyqszguz.jpg.html')

The pipe and the hose are from a BMW E39 530D, after i have used the 530D intercooler pipes and hoses in serveral cars, it seems that they can be used in every engine bay and every engine.

3. Boost Leackage (not very good)
During the installation i have loose and retighting a clamp at the joint of the intake manifold and after that i could only achive 0.2 bar of boost pressure and a load whistle. The hose and the intale manifold do not fit optimal in reagrd of the angle and the diameter. As quick and dirty solution i have used a third clamp and after that, the whistle was gone (or better not detectable) and i could achive a max boost pressure of 1,25 bar.


4. Power (good) - Spooling (not good)
As written earlier i have done some test drives with the g-tech and with the new data i think i can jude the power and the spooling behavior quite accurate. Power is quite good, but the spooling is really bad. Subjektive it did not feel that bad, which shows again that you have to measure to get knowledge, otherwise you stay unknowing and have to believe.

Here are the diagrams:
red / blue are the actual test data, with the twinscroll S2A and QSV and approximate 1,5 bar
green is the test data from 2012 with the old S2A and nearly 2,0 bar boostpressure (this was dynoed with 190 hp)
black ist the test data from 2013 with the big S2B and QSV and approximate 2,0 bar boost pressure. (no dyno, g-Tech suggest 200+x hp)

First power vs. engine speed in third gear
(the green is measured in second gear)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/20160403_Golf2-GTD_G-Tech_Leistung_P-vs-n_2012-2013-2016_zpsd3xg8wae.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/20160403_Golf2-GTD_G-Tech_Leistung_P-vs-n_2012-2013-2016_zpsd3xg8wae.jpg.html')

The green curve can not be judged regarding their shape, as this was not taken as a "real" power run and i have accelerate in a different manner. It can be ssen that the actual max. power is nearly identical with the 190 hp setup from 2012 (can also be seen in the later 1/4 mile measurements). It can also be seen, that the spooling is much worse than with the bigger S2B with QSV in 2013, which make no sense in my eyes. The spooling is nearly identical whith the spooling of the bigger S2B before the QSV was installed. Why - i dont know. As written above, my maximal achivable boost pressue was reduced to 1,25 bar at the last test drive, it could be that there was a boost leakage or the wastegate leaked, or both. During the last test run i disconnect the boost line to the wastegate, so this should stay fully closed, but could not increase the boost pressure anything above 1,25 bar.

Here are g-force vs. speed

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/20160403_Golf2-GTD_G-Tech_Leistung_g-vs-v_2012-2013-2016_zpspkpphvgj.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/20160403_Golf2-GTD_G-Tech_Leistung_g-vs-v_2012-2013-2016_zpspkpphvgj.jpg.html')

The green line is also not valid before it is nearly identical with the blue line. It could also be seen the the g-force in third gear is also nearly identical to the 190 hp setup from 2012.

And at least power vs. speed (the lower blue curves are wheel- and accerlerate-power)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/20160403_Golf2-GTD_G-Tech_Leistung_P-vs-v_2012-2013-2016_zpsphcxcf5o.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/20160403_Golf2-GTD_G-Tech_Leistung_P-vs-v_2012-2013-2016_zpsphcxcf5o.jpg.html')


And hier the same diagrams for the 1/4 mile test runs (green curve was a second gear start)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/20160403_Golf2-GTD_G-Tech_Meile_P-vs-n_2012-2013-2016_zpsszq9egac.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/20160403_Golf2-GTD_G-Tech_Meile_P-vs-n_2012-2013-2016_zpsszq9egac.jpg.html')

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/20160403_Golf2-GTD_G-Tech_Meile_g-vs-v_2012-2013-2016_zpsfcmerv6y.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/20160403_Golf2-GTD_G-Tech_Meile_g-vs-v_2012-2013-2016_zpsfcmerv6y.jpg.html')

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/20160403_Golf2-GTD_G-Tech_Meile_P-vs-v_2012-2013-2016_zpsxf4qyjd1.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/20160403_Golf2-GTD_G-Tech_Meile_P-vs-v_2012-2013-2016_zpsxf4qyjd1.jpg.html')

The summary is, that the power is actual a bit below 190 hp, as i have measured in 2012, but with less torque and much worse spooling behavior.

At least here are one more diagram with a power curve in third gear with reduced boost pressure of 1,25 bar (the dotted line is curve from above with approximate 1,5 bar). According to the test data, the decrease in boost pressure means a reduction of 20 hp peak power, which is in line with the subjective feeling.

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/20160403_Golf2-GTD_G-Tech_Leistung_P-vs-n_2012-2013-2016-2u3_zpskgxplld4.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/20160403_Golf2-GTD_G-Tech_Leistung_P-vs-n_2012-2013-2016-2u3_zpskgxplld4.jpg.html')
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 04, 2016, 04:53:41 pm
5. What then happend (absolutely not good)

As dicussed above, the last test run did not ended as sheduled. On the drive home, i was happy with the golf, even with the non optimal spooling behavior and gave the engine some extra diesel from time to time.


Shortly bevore i reached my home, at a respectable speed, full boost pressure and valueable engine speed a very loud bang occure and than silence - only the wind the golf and i - why is it so quite here?  - this must be happend sometimes - or only some small defekt? - why is the car decelerate at this high rate, whithout usinf the brakes? - decoupling? - f..ck - that is no small issue.

This happens 10 days ago and yesterday i could make a short inspection. Even after it was clear that there was some major issue with the lower engine part, i was suprised about the extent:


(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0963_zpsfknayglv.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0963_zpsfknayglv.jpg.html')



(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0965_zpsidzxq5me.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0965_zpsidzxq5me.jpg.html')



(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0966_zps2jqmdx7s.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0966_zps2jqmdx7s.jpg.html')



(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0968_zpsylqzrcnm.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0968_zpsylqzrcnm.jpg.html')



(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0970_zps8ag28x4e.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0970_zps8ag28x4e.jpg.html')



(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0971_zpsvxmooy0e.jpg) (http://'http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0971_zpsvxmooy0e.jpg.html')

The engine block is cracked at the backside complete from the cambeld side to the gearbox side.

What to do next, i do not know - 1.6 franken engine - 1.9 TDI (afn) - 1.9 TDI (ALR) ? I am open for recommendations

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on April 04, 2016, 09:56:22 pm
Wow this is very sad news.  It seems the aaz only likes so much power before the bottom end gives out.  Did you have upgraded rods or bottom end hardware?  I'd recommend an alh with mechanical pump, a Franken 1.6 could be nice because you could reuse your head and turbo assuming they are still good.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: GTiTDi on April 05, 2016, 09:15:54 am
Schlecht :( Time for a TDI I would say! I love my 1Z powered mk2 :D https://forums.tdiclub.com/showthread.php?t=304978
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 10, 2016, 03:39:10 pm
Hi,

just as a short notice:

i though a while - TDI vs. non TDI, but in the end i make a decision an bought an 1.6 TD engine today, so my Golf will go back to the roots with a orignial MK2 engine.

Some more details soon.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on April 11, 2016, 07:56:45 am
have you disassembled the old engine to see what has failed?  this really sucks to have happened right after you got the car back on the road.  but it will be cool to see how the 1.6 runs now.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 23, 2016, 02:53:39 pm
Hi,

@RabbitJockey
No i did not turn a screw after bring the car in my garage. I have had changed the cylinderhead on my E34 525TDS in the last weeks and still have a few things to do on the bimmer (i also use a grinded cam and and swap the turbo to a mechanical controlled GT2556V VTG turbo)

@GTITDI
Very nice built, i have read all pages in the last days, which makes my wand a TDI a bit.

@all
The guy were i bought the 1.6 TD engine, did not send me his bank data, so that i could not pay and afterwards tells me that he have rethought the sale and will no longer sell the engine. We did have agreed on phone on all details, so it is a bit strange, but "Was willste tun"

So i am back in the game to decide, what the next engine should be. In general i am looking at AFN and SB engines, but AAZ is also still an option. Today we found a very very mind Golf MK2 GTD Special in Oak-green (best condition which i have seen in the last 5-10 years) for a very reasonable price, so we phoned the guy and was willing to buy the car at the phone, but it was sold allready. In that case i would have used my car only for parts and wolud have driven the original GTD speciale.

Then there is an offer for a complete AFN package for a MK2, installed in a MK2, so it is possible to make a test drive. This would work for me either, but i could not reach the guy until now.

Best Regards
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 24, 2016, 03:49:06 pm
Hi,

i have had a phone call regarding the AFN Package and i think i will buy it (to be honest, i send him a message that i will buy it). The guy offers tdi engine swaps as his job and the golf, where the engine is actual in, is also done by him (customer car, not his own). Because i have realy little to no time, i play with the tought to bring him my golf and let him change the complete package. I also asked him, if i could buy the hole car, but he still needs some parts (it is a golf syncro). I wand to avoid to speak from a "complete package" and afterwards spend hunderts of euros for a few small OEM parts, because this and that is missing, to make it running again.

Best Regards
Alleslowbuged 
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on April 25, 2016, 03:51:50 pm
complete swaps or swap cars are always smart to use.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: vanbcguy on April 25, 2016, 04:29:05 pm
AFN will be a great engine for you - tons of potential there!
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on December 08, 2016, 05:59:40 pm
Hi,

the guy did not call me back and i do not get him back to the phone in April, so nothing happend until now. But today i buy an Golf MkII with an AFN engine, and bring it to my garage. I will use the engine the electronic from the new golf for my red golf, so my TD will get an TDI.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on December 09, 2016, 02:50:02 pm
great, is an afn an 058 block?  will you be experimenting with the same turbos still?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on December 09, 2016, 05:39:55 pm
Hi,

i do not know the block code, but it should be the same as 1Z / AHU and the earlier type 1.9 TDI's. I think the AFN was the first with VTG turbo and it have a more step (4,1mm) camplete  in the injecton pump. The stock power is 110hp.

I will go for VTG turbo, but bigger than stock, or to say biggest i find. My daily driver is a BMW E34 525TDS since a couple of years and i am running a GT2556V (E39 530D) with boost can an electronic boost controler. The BMW has an autobox and do not see to high rpm's quite often, the boost control with the electronic boost controller works quite well, i only have slightly overboost by going full load after no load at higher rpm's. Which turbo i use is still open, i could end up with a GT1749V / GT2052V hybrit, an GT2056 or even an GT2556V, as i have experience with the turbo and they are cheap to buy. I also think about the manifold, if i should use the stock manifold or use the one, i have used on the AAZ engine.

The benfit of VTG are to high to go forward with wastegate turbo's for me. With wastegate's you have either big lag or big power restriction and high egt's or you need a perfect turbo and are willing to go 2,0 bar or more at high rpm's. The other benfit of VTG turbos is the more easy package, because you do not need external wastegates.

Regarding my swap, yesterday everthing seems to be clear and i was willing to take over the whole package including the hole electronics, but now i think again if mtdi could be more fitting to me. I like the idea of being in full control for fuel with a screwdriver and 13mm spanner.

As summary the hole engine build is not fixed in my head. What is for sure is that i will rebuild the head, use a regrinded camshaft, go back to organic sachs performance coupling and will use a bigger VTG turbo. The pump will 11 or 12 mm plunger with AFN camplate and i have no idea what nozzles to use. I like to have to the pump, turbo and nozzle be ready for 200hp+ and will be happy with everthing above 180-190 hp.


Best Regards
Alleslowbuged   

   
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on December 14, 2016, 06:00:28 pm
Hi,

i am get some progress in my overall plan, actual it looks like 200hp with matching hardware to make it reliable.

fixed (nearly) shedule:

- ported head, pherhaps with bigger valves,
- regrinded camshaft
- ARP head bolts
- GTB2056VK Turbo
- 0.260er Nozzles
- d=11 (pherhaps d=12) plunger for the injection pump
- custom intake - Volvo 5-cylinder

open shedule:

- Exhaust manifold (tubular type - facing down, or the same as before - facing up)
- intercoller (stock GTD as before, or front mounted)
- IP elektronic / mechanic oder mechanic with electronic timing control

I know that using the full electronic package would be the best solution, but the idea of an 200hp TDI in an MKII Golf, with an mechanical pump, upfacing turbo and stock GTD intercooler, which looks like the stock 1.6TD at the first glance, is very appealing to me.

I do not have any experience with M-TDI's, so i do not have any experience if it is possible to handle that properly. I would like to use a mechanical pump with electronic timing control, as in the latest AAZ's, because i think that is the weakest point of the mechnical package. I have had the thougth of swapping the hole package and than swap the pump to an mechanical with elec. timing control and only conect the PWM valve to the harness. But i do not know if the ecu will work, when the pump head is not conected and i would need e-throttle and cable at the same time. So only woolgathering.

Best Regards
Alleslowbuged

Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on December 15, 2016, 11:03:35 am
058 would be ahu/1z style 06a is later internal water pump style like an alh.

i think keeping the gtd intercooler would be fine, you have shown with your aaz that it did not seem to limit power

you may want to have the exhaust manifold facing up because of the rear engine mount

your pump is easy in either direction, the land rover pumps have been show be great pumps which are easily adapted to work on a vw engine.  you already have experiencing with modding the pump.  but this route will make controlling the vnt turbo challenging, or you could run your old turbo and manifolds, it all bolts up, no need to spend more money.

electronic pump is also very easy if you swap in a passat pedal assembly then the drive by wire hardware is all in place, and it makes controlling a gtb2056vk easy.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on December 23, 2016, 06:50:15 pm
Hi,

i have increased my power goal to 230hp and have ordered a ported head with 37/33 oversized valved and a performace cam with 9.5mm lift today. I would have liked to use a 10mm cam, but than i must have pulled the pistons and machine the valve grooves.

The turbo has also changed to a GTB2060VKLR with ball bearings, vacuum control and a T3 flange, which will be installed on my kinetic manifold, so general arrangement will be as with the AAZ.

Due to the increased power goal i will also using bigger nozzles, but i struggle to decide if either 0.28 oder 0.32 would be better. The pump will be with electronic control and i will use the 12mm plunger from my mechanical pump. I was told to use the camplate from an ALH pump (DE134), did anybody here knows what stroke that has and if there is an different to the AFN camplate with 4,1 mm stroke?

So the plan is ready and i need parts and time to install them. I have also started to strip the AAZ, but the cylinderhead is still in place so i do not know how the cylinder and pistions looks, but i will make pictures if the head is down.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on December 30, 2016, 06:10:08 pm
Hi,

here are some pics as update and keep the thread a bit more alive, as only a lot of text.

This is "my" Golf last week:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_1623_zpstsnrycgf.jpg) (http://"http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_1623_zpstsnrycgf.jpg.html")
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_1624_zps74ejpqpq.jpg) (http://"http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_1624_zps74ejpqpq.jpg.html")

and this is from wednesday:

head pulled:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_1650_zpstodse6v2.jpg) (http://"http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_1650_zpstodse6v2.jpg.html")

search for the failure (tip: keep an eye on all pistons)
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_1651_zpsiet6o96s.jpg) (http://"http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_1651_zpsiet6o96s.jpg.html")

some extra ventilation for the oil pan
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_1655_zpspaeo2zas.jpg) (http://"http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_1655_zpspaeo2zas.jpg.html")

The head looks and feels fully ok
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_1648_zpsp9wdx9zo.jpg) (http://"http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_1648_zpsp9wdx9zo.jpg.html")

if someone want a ported AAZ head with regrinded camshaft, valves seats mashined to run with stock bottom end and ready for 190hp, here it is for sale:
 
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_1649_zpst68jdgeq.jpg) (http://"http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_1649_zpst68jdgeq.jpg.html")

and here are some pics of the donor car, it is a little bit a shame to strip it back:

Golf MKII
- plus axles with 5x100 and 288er brakes
- e-gas and hydraulic clutch actuator
- e-windows
- central locking
- full converted wiring loom to fit AFN engine with fully working seat ibiza tacho with MFA
- 02a gearbox
- good interior
- power steering
- etc..

first day:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/Abholung-AFN-Golf_zpsm0phavwx.jpg) (http://"http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/Abholung-AFN-Golf_zpsm0phavwx.jpg.html")
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_1616_zpspurweykl.jpg) (http://"http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_1616_zpspurweykl.jpg.html")
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_1617_zpshtwyobyx.jpg) (http://"http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_1617_zpshtwyobyx.jpg.html")
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_1618_zpsgjbe2j9m.jpg) (http://"http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_1618_zpsgjbe2j9m.jpg.html")
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_1619_zpsbfgswjzr.jpg) (http://"http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_1619_zpsbfgswjzr.jpg.html")

wednesday:
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_1627_zpssnjzovsj.jpg) (http://"http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_1627_zpssnjzovsj.jpg.html")
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/AFN-Golf-auszligen-1_zpsk5qklhsv.jpg) (http://"http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/AFN-Golf-auszligen-1_zpsk5qklhsv.jpg.html")
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_1631_zpsccqwp0km.jpg) (http://"http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_1631_zpsccqwp0km.jpg.html")

I am realy happy that i could fix the "no power" issue today, because now i know i can swap 1:1 all the parts and the engine will run in my golf also.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on December 31, 2016, 02:14:59 pm
Hi,

i have ordered an AFN pump with 12 mm head and DE110 camplate (3,1 mm stroke) today, so that is fixed also.

Best Regards and a nice to 2017 to everybody
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on January 04, 2017, 03:16:48 pm
Hi,

i came to a conclusion regarding the nozzle size. As written i was unsure if 0.260 or 0.280 would be best and came up with the following thoughts:

The Afn has 110hp, a 10mm pumphead and 0.205 nozzles as stock and i would say that there is at least 20% margin left in regard of fuel / power without sacrificing injection time duration to much. So i can say, a 10mm pump head and 0,205 nozzles are good for min. 132 hp with suitable injection time duration and good atomisation.

When i go from 10mm head to 12mm head this means an increase of 44% in regard of flow per stroke (assuming that the volumentric effeciency is the same , even if it is not the same at high rpms). So by increasing nozzle size also by 44% should bring similiar injection time duration, injection pressures and atomisation @ 44% higher fuel rate and therefor 44% more engine power. This would mean 190hp and 0.246 nozzles.

So to go over 190hp means either bigger pump head than 12mm, or increase injetion time durartion to get more flow, or sacrificing atomisation by using bigger nozzles. As i want to rev to a certain level, bigger pump head is no option.

So its injection time vs. atomisation to find the best compromise. The nearest available nozzle options are 0.260 and 0.280, which means 14% vs. 30% higher flow rates above the calculated 0.246. In engine power this would mean 216 hp vs. 246 hp with a similar injection time duration as a stock AFN with a 20% remap, but worsen atomisation.

I think based on this thoughs both nozzles sizes would be still an option, but it is clear that the 0.260 nozzle will not have much margin left @ 230hp in terms of suitable injection duration times. Adding the fact that the 12mm head will loose some of its volumetric efficiency at higher rpms, the margin will be even smaller, even if i have no doubt that 230hp will be possible with 12mm head and 0.260 nozzles.

My shedule is to use 0.280 gibonta nozzles, mainly because i am concerned about the cambelt and the high pressure plunger. If i would use a 12mm head with 0.246 nozzle @ 190hp, this would mean approximate 44% more torque for the pump plunger and the cam belt to handle. For the 0.260 and 0.280 nozzles @ 230 hp i am not so sure about the percentage increase in torque, because both will end up with lower injection pressures, but it is for sure that the 0.280 nozzles will stress the pump and the cam belt less than the 0.260 nozzles.

Just to make clear, i know that all this is only a simple a linear approach and the reality is bit more complex, but as we speaking about a fluid as medium i think the approach as above, should be suitable for getting some rough numbers to orientate. To realy see the mentioned power figures there should be enough air to burn all the fuel injected as well, but this is another topic.

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on January 05, 2017, 08:49:51 am
it does seem like a waste of energy to swap engines... maybe just enjoy both cars some how?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on January 05, 2017, 08:50:30 am
also what happened that allowed the pistons to hit the valves?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on January 05, 2017, 04:10:45 pm
Hi,

@RabbitJockey

I agree, that it would make more sence to keep the black golf together and just make it better with parts from "my" (red) Golf. But it would have make even more sence to buy an MKIV with an stock AHF / ASV engine and just bolt some parts on it. If you have make a Golf MKII ready to cope with 200hp, the weight advantage shrinks to just a fraction.

To be honest, i mainly keep my golf, because i have some kind of relationship to all my cars and after having a lot of ups and downs (more ups) over a couple of years, it seems just not fair to jump in next best car available and forget the old one. It is also not good for the KARMA -- a friend has swaped her motorcycle to a newer one of the same model, just because it was newer and than has only has problems the hole year. The old one was bougth as new by her and never missed a beat over serveral years.

The black golf is worse than the pictures suggest, but not bad at all. At least it would also need some work to finalize and there are also some pros for my golf, it has PU bushings all around, widen weel arches to fit et13 rims and look nearly oem, brand new rear disks, new front subframe, front splitter, nicer interior and at least it is red (i like red more than black on cars).

Best Regards
Alleslowbuged

P.S. I try to convince my friend, who will help me with the engine swap, that he wants the black golf and i suggest that he will organize a new AAZ block and we will put a new AAZ (~160-170hp) in the black one.
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on January 05, 2017, 04:59:54 pm
Hi,

here are some pics of the intake:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0762_zpslmqw22x2.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0762_zpslmqw22x2.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0763_zps99qfwrvh.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0763_zps99qfwrvh.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0764_zps5joy2255.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0764_zps5joy2255.jpg.html)

looks good
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0769_zpszwab1ajh.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0769_zpszwab1ajh.jpg.html)

not so good
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0770_zpsd2mqx5zj.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0770_zpsd2mqx5zj.jpg.html)

comparison with Pd150 intake
(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0781_zpsxxytonpk.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0781_zpsxxytonpk.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0785_zpsmviozgru.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0785_zpsmviozgru.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0786_zpslczuedzd.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0786_zpslczuedzd.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0787_zpsumuuhldf.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0787_zpsumuuhldf.jpg.html)

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/DSC_0788_zpsk9h4mjty.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/DSC_0788_zpsk9h4mjty.jpg.html)

I would love to increase the volume of the plenum and make it a dual plenum, but i can not weld alu und all my attemps to built a "custom" intake did not went well - pherhaps somtime in the future
 
Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on January 20, 2017, 05:04:15 pm
Hi,

so not much news here. The head and intake are in finnland, the pump and the 0.280 gibonta nozzle are here and wait for installation. I have wait a few day for feedback from the turbo supplier, but get his feedback now. I will send him my manifold an my last used Schwitzer S2A turbo as template, so that he can adjust postion and degree of rotation of the turbo.

Best Regards
Alleslowbuged 
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on February 19, 2017, 05:44:06 pm
​Hi,

the head is ready, i get pictures from the porting guy today:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/AFN%20TDI/IMG_5245_zpswfqfbm1h.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/AFN%20TDI/IMG_5245_zpswfqfbm1h.jpg.html)


(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/AFN%20TDI/IMG_5244_zpshrdnfkap.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/AFN%20TDI/IMG_5244_zpshrdnfkap.jpg.html)


(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/AFN%20TDI/IMG_5243_zpsnwpexoma.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/AFN%20TDI/IMG_5243_zpsnwpexoma.jpg.html)


(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/AFN%20TDI/AFN_flow-diagram_nps_20170219_zpsvodn46rw.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/AFN%20TDI/AFN_flow-diagram_nps_20170219_zpsvodn46rw.jpg.html)

I am counting days (weeks) now...

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on February 19, 2017, 05:55:41 pm
Hi,

i forget the intake manifold:

(http://i702.photobucket.com/albums/ww24/euro-styler/Golf%202%20GTD%20AAZ/AFN%20TDI/IMG_5242_zpsmipaivk7.jpg) (http://s702.photobucket.com/user/euro-styler/media/Golf%202%20GTD%20AAZ/AFN%20TDI/IMG_5242_zpsmipaivk7.jpg.html)

Best Regards
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on May 24, 2018, 09:57:04 am
Hi,

good news, Photobucket is back in business and therefore my pictures are back.

Best Regrads
Alleslowbuged
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: RabbitJockey on May 29, 2018, 08:30:48 am
hello, how is the mk2?
Title: Re: Golf II GTD with 1.9 AAZ engine --- EVO II
Post by: Alleslowbuged on April 29, 2021, 06:11:58 pm
Hi,

not so muchs news here.

The red golf (TD) is still sitting with the cracked block and waiting for my attention.
The black golf (TDI) is regularly used to drive to 5min around the shop and also waits for usage.

In additon i have bought a white golf (TDI also AFN), which i have driven for a year as daily driver. One and a half year ago it makes some strange noises and as i did not have time to work on it, i bring it to the official car repir shop from a friend, so that it will not end as the other two. Now 1,5 years later i take it home in parts, because he refuses to get it together. In the end, the only option is to do it yourself.

So currently i work out out to put it all together, which is a bit more difficult as i am used to, as i am a) not an expert for DI engines and b) i did not disassemble the engine.

But at least for now i am think it will work out.

Best Regards
Alleslowbuged