Author Topic: Tuning 1.9TD by using a hybrid turbo - A few questions!! (Read 33043 times)

foxracer1 · « **Reply #15 on:** October 11, 2008, 08:10:44 am »

Tractor pullers run over 200psi, plus lots of fuel and water/meth injection and much abuse to the clutches. :twisted:

I'd try a T3 if i was you. I love mine and my engine isn't 100% so i can only imagine a healthy 1.9.

Otis2 · « **Reply #16 on:** October 11, 2008, 01:32:16 pm »

Quote from: "cyrus #1"

Dumping ass loads of fuel into the engine means there is more heat coming out of the motor. On diesels, generally more fuel = more boost. :twisted:

Indeed.

There are a number of us on this board that drive with our turbo's wastegates intentionally disconnected.

Peak turbo boost is governed by the position of the max fuel screw on the pump with the wastegate disconnected. That is, the turbo will spool up to whatever pressure the injection pump is dialled to support.

I had my max fuel screw set on the pump to allow 20 psi from the turbo at full throttle for a while, now I screwed it back to allow more like 16 - 17 psi at full throttle, and I'm happy.

With the max fuel screw turned up, I have to feather the throttle pedal a bit at low engine speed (before boost builds), otherwise I get a bit of black smoke at the tailpipe. But if I wait until the turbo spools up a bit, then I can slam the pedal and there's no smoke at all, just lots of boost pressure & power.

vwt4 · « **Reply #17 on:** October 14, 2008, 01:56:06 pm »

Quote from: "Otis2"

Quote from: "cyrus #1"
Dumping ass loads of fuel into the engine means there is more heat coming out of the motor. On diesels, generally more fuel = more boost. :twisted:

Indeed.

There are a number of us on this board that drive with our turbo's wastegates intentionally disconnected.

Peak turbo boost is governed by the position of the max fuel screw on the pump with the wastegate disconnected. That is, the turbo will spool up to whatever pressure the injection pump is dialled to support.

I had my max fuel screw set on the pump to allow 20 psi from the turbo at full throttle for a while, now I screwed it back to allow more like 16 - 17 psi at full throttle, and I'm happy.

With the max fuel screw turned up, I have to feather the throttle pedal a bit at low engine speed (before boost builds), otherwise I get a bit of black smoke at the tailpipe. But if I wait until the turbo spools up a bit, then I can slam the pedal and there's no smoke at all, just lots of boost pressure & power.

Thanks for the info Otis :wink:

Can anyone please confirm a few things for me...

If I change the pump top to the 1.6 one, will this allow my pump to increase fuel to match increased boost?

I have been informed that the pump top on a standard ABL pump doesnt add more fuel with boost, but with the boost pin from a 1.6 the fuelling will be much better for higher boost?

Also, What injectors should I fit if I am aiming for 130-150hp using a hybrid turbo> and does anyone know if there are any good 'donor' injectors? (eg/ off another car that i can get from a breakers yard etc)

Thanks!

ps// Is my goal realistic? with the following

K14 turbo and manifold or adapter to suit
Intercooler and hard pipes
1.6 boost pin and fuelling screw dialled in to suit
EGT gauge - I already have fitted a boost gauge.

What am I missing or should I add/change?

Baxter · « **Reply #18 on:** October 16, 2008, 03:13:12 pm »

T4's aren't light.
I would do mods in this order..

EGT gauge.
Boost gauge.
EGR delete.
Find a pump top with a LDA as the ABL doesn't have one.
Fit oil cooler (heavy van, the engines don't last anyway in stock form, messing with one is only going to kill it sooner)
Fit intercooler.
Start messing with boost and fuel.

Don't just go straight for the fuel screw and turn the boost up or it will end in tears.

Simon.

Smokey Eddy · « **Reply #19 on:** October 16, 2008, 04:09:52 pm »

Quote

Don't just go straight for the fuel screw and turn the boost up or it will end in tears.

x100

Quote

EGT gauge.
Boost gauge.
EGR delete.
Find a pump top with a LDA as the ABL doesn't have one.
Fit oil cooler (heavy van, the engines don't last anyway in stock form, messing with one is only going to kill it sooner)
Fit intercooler.
Start messing with boost and fuel.

+1
That's a very good list IMO. add in bigger exhaust before messing with fuel is my advice. thats more of a heads up as more fuel will spike EGT's without an easier/faster way of getting the heck out of the head. Look into making a 3 inch downpipe too. there are some really nice ones on this forum. there are some recent ones actually so i don't even think you need to use the search.
Our IDI's don't need cats or mufflers

maybe keep the cat in the basement for emissions control time :roll:
(someone may correct me, is it not a cat just a resonator?)

vwt4 · « **Reply #20 on:** October 23, 2008, 09:42:19 am »

Thanks Baxter

Thats a great list. If a little more costly than I was hoping!!
Still, I suppose it will be cheaper than doing it 'wrong' and blowing my engine up.

Smokey Eddy - thanks also re the DP and exhaust suggestions.
i will do this as well

Can anyone tell me where on earth I can get a 12mm Pump Top from?

I have been advised to get one by a T4 diesel tuning guru (his van is 380 hp and 1/4 mile in 14.6 secs!) but I cant find one for love nor money!!

johnboy · « **Reply #21 on:** October 24, 2008, 12:14:09 pm »

The ABL is basically a AAZ with some differences to make it suit in the T4's engine bay, the main ones being that the turbo is mounted at a different angle and therefore uses different manifolds and the pump has no LDA, other than that they are virtually identical in all respects. Anything you can do to an AAZ you can do to an ABL.
Id fit a LDA or complete pump straight off a AAZ engine first, then have a play with the boost and fueling.
The only problem you may have in fitting an LDA is that I think it would be VERY close and may foul the radiator. Im probably wrong, but it'd be would be worth taking some measurements before investing in a pump or LDA.

vwt4 · « **Reply #22 on:** October 24, 2008, 05:35:02 pm »

Quote from: "johnboy"

The ABL is basically a AAZ with some differences to make it suit in the T4's engine bay, the main ones being that the turbo is mounted at a different angle and therefore uses different manifolds and the pump has no LDA, other than that they are virtually identical in all respects. Anything you can do to an AAZ you can do to an ABL.
Id fit a LDA or complete pump straight off a AAZ engine first, then have a play with the boost and fueling.
The only problem you may have in fitting an LDA is that I think it would be VERY close and may foul the radiator. Im probably wrong, but it'd be would be worth taking some measurements before investing in a pump or LDA.

Thats VERy useful information johnboy!!!

Thanks a lot mate :wink:
There is loads of room at the front of the T4 engine bay (between the pump and rad. Hopefully fit wont be a problem!)

Which is the easier job///?
The pump top swap or the whole pump? (not done one yet but Im brave and confident!!!)

Am I right in thinking 1.9TD passats, seats, golf mk3s.All apart from the ECO diesel, which apparently can be identified by the lack of LDA and small boost pipe from the inlet manifold to the LDA(top of the diesel pump). It does not increase fuel as the boost increases, it just uses the turbo boost to stop any smoke rather than to add power!!!

dillenger1 · « **Reply #23 on:** October 25, 2008, 02:02:43 pm »

You can get a 12mm head from a cummins pump.Or some tdi autos have an 11mm assembly,But id do some reseasrch.Id be ready to swao out other pump parts as well like the camplate and springs maybe delivery valves.Your also gonna have to tune it by ear as timing will be off.You can get a 10mm assembly from a peugoet td.

Baxter · « **Reply #24 on:** October 26, 2008, 01:59:06 am »

Differences between ABL and AAZ that I am aware of...

ABL has an extra water outlet on the head, only small, it goes to the header tank.

ABL block isn't drilled for a dipstick tube.

At some point the valve stem size on the AAZ reduced from 8mm to 7mm, these apparently flow better.
I don't think this happened to the ABL and they all have 8mm valve stems.

Then, obviously the injection pump.

vwt4 · « **Reply #25 on:** October 27, 2008, 05:37:52 pm »

Quote from: "Baxter"

Differences between ABL and AAZ that I am aware of...

ABL has an extra water outlet on the head, only small, it goes to the header tank.

ABL block isn't drilled for a dipstick tube.

At some point the valve stem size on the AAZ reduced from 8mm to 7mm, these apparently flow better.
I don't think this happened to the ABL and they all have 8mm valve stems.

Then, obviously the injection pump.

Thanks Baxter

which brings me to my next question....

Have you got any used AAZ pumps or pump tops in stock so to speak?

regcheeseman · « **Reply #26 on:** October 28, 2008, 03:06:55 pm »

Dunno about your T4, but I went to fit a boost controller to a mates T4 the other day and was dismayed when I looked under the bonnet and found a tiny turbo and a pump with no LDA.

I told him I could get more boost but there really was no point without boost enrichment.

I fitted it anyway and he got 15psi no bother - maybe more we didn't try as there just wasn't the fuel there.

Loads of room in a T4 bay?

? ha ha ha ha ha ha ha ha maybe for turbo access but you try getting to the pump.

vwt4 · « **Reply #27 on:** November 19, 2008, 06:43:45 am »

Quote from: "regcheeseman"

Dunno about your T4, but I went to fit a boost controller to a mates T4 the other day and was dismayed when I looked under the bonnet and found a tiny turbo and a pump with no LDA.

I told him I could get more boost but there really was no point without boost enrichment.

I fitted it anyway and he got 15psi no bother - maybe more we didn't try as there just wasn't the fuel there.

Loads of room in a T4 bay?? ha ha ha ha ha ha ha ha maybe for turbo access but you try getting to the pump.

Agreed Reg

Theres sod all room for access to the pump :lol:
Good point. I was thinking more around the turbo and top of the engine!

molgrips · « **Reply #28 on:** November 19, 2008, 08:01:55 am »

Johnboy, you have the exact same car as me in the same colour, with the exact same mods and the same planned mods.

Big up the UK crew on this thread.

regcheeseman · « **Reply #29 on:** November 20, 2008, 05:27:22 am »

Quote

Good point. I was thinking more around the turbo and top of the engine!

No point even touching that turbo, it'll boost to 15 psi which is enough for a stock motor and should give you 120 brake easily......with the right pump.

Quite easy to lift the rad off on the T4, makes it much easier to work on, watch out for the power steering cooler...