Jetta project 200

[theman53]

My machinist has a formula worked out. Your Plenum volume should be 1/2 of your displacement. So a 2.0L engine would have a 1.0L plenum. He has developed some racing and street engines with another guy and they have found that the best all around combination is just that 1/2 of engine displacement. Less than that and you run into high rpm issues and more than that you have more lag/throttle response. I am almost done with my intake and I have just a pinch over .8L or 49cu/in. I will let you know how it works but in theory it should work fine.

TurboJ- Yours maybe fine or if it seems like you wish you had more throttle response you might want to try a touch smaller...or more displacement

[carrizog60]

can you summarize the improvements on the water cooling capabilities?

[TurboJ]

My machinist has a formula worked out. Your Plenum volume should be 1/2 of your displacement. So a 2.0L engine would have a 1.0L plenum. He has developed some racing and street engines with another guy and they have found that the best all around combination is just that 1/2 of engine displacement. Less than that and you run into high rpm issues and more than that you have more lag/throttle response. I am almost done with my intake and I have just a pinch over .8L or 49cu/in. I will let you know how it works but in theory it should work fine.

TurboJ- Yours maybe fine or if it seems like you wish you had more throttle response you might want to try a touch smaller...or more displacement

I sure hope it will be fine.. I'm beyond the point of no return now. The exhaust mani, turbo and all compel me to use exactly this inlet - besides I really love its overall design and how Aki has made it fit my system.. I know the general rules for plenum sizing, and that's exactly why I was wondering about this.. But I feel my special pump, small diameter boost pipes, lightened flywheel etc. should give quite good throttle response, and that should allow me to trade some of that on the inlet mani for better high revs operation. I hope this at least!

[TurboJ]

can you summarize the improvements on the water cooling capabilities?

You mean what I have done to improve my water cooling system?

Well, here's what:

- Bigger radiator out of a Passat B4 1,9 TDI Auto with A/C
- Air baffles all around the radiator and the car's nose to keep most air from going round the rad
- Oil-to-water heat exchanger ditched and replaced by an oil-to-air cooler with a thermostat
- Cooler thermostat
- Bigger radiator fan with the option of a dual fan setup if needed
- Cooler rad fan switch with a manual override feature

...and I'm going to run Redline's Water Wetter in the coolant, and also use a leaner mixture of regular coolant for maximum heat transfer

BUT. I'm still worried about my cooling, because there's almost no air flow to the radiator except through the other three radiators...
Maybe I will drill some holes to the bumper anyway 

[TurboJ]

Interesting.
Id think your volume would be still relatively in proportion, as you have removed  2 cyls from it, though who knows what VW optimized it dfor or how much effort they put into it.

Yeah, the plenum sizing is curious...
It's a VW LT 2.4 TD manifold originally, and of course the plenum with an intact LT manifold would be proportionally just as big as on my 1.6.
So, why would the factory put this big plenum SRI on a van ??
Such an intake should work best on a high-revving, high power engine rather than a work horse.

[TurboJ]

Did some work on the intercooler today.
My trusted TIG welder had welded the inlet and outlet in place:







If you're wondering why the curves are different radius on the inlet and outlet - well - I was lucky
The water radiator fitment necessitated a tighter curve on the inlet, which is nice since on the inlet side it has less of an ill effect on the flow.
Hence , the smoother bend is exactly on the right side.


I then continued on the air baffles, or their final insulation to be exact:




There it is!





It was really a lot of work, a lot... To make it fit. Because really, there was absolutely no extra room on any side of the I/C. On some places
it was a question of less than a millimeter of clearance! Taking into account the flex fittings of the I/C of course..

Can you spell T_I_G_H_T  ?








But believe it or not, it doesn't hit anything even when fully twisted to any possible angle on the rubber mounts. The smallest margin is the 1 mm though 
Now I'll have to leave the I/C alone as I have to drop the engine in the bay before I can do any more work on the pipework. Tomorrow hopefully the manifolds and turbo
will go on 

[745 turbogreasel]

So, why would the factory put this big plenum SRI on a van ??
Such an intake should work best on a high-revving, high power engine rather than a work horse.

When it came to America in the Volvo 740, it was the fastest diesel  car on the market, although in my experience the BMW 2.4 is really close.  Maybe the BMWs just haven't got as worn out in the last 20 years.

The D24 doesn't really like being driven as  a low rev motor.  It's got just enough torque to loaf along on the freeway without much boost, but to do anything more, you have to drive it like a 1.6.

[carrizog60]

can you summarize the improvements on the water cooling capabilities?

You mean what I have done to improve my water cooling system?

Well, here's what:

- Bigger radiator out of a Passat B4 1,9 TDI Auto with A/C
- Air baffles all around the radiator and the car's nose to keep most air from going round the rad
- Oil-to-water heat exchanger ditched and replaced by an oil-to-air cooler with a thermostat
- Cooler thermostat
- Bigger radiator fan with the option of a dual fan setup if needed
- Cooler rad fan switch with a manual override feature

...and I'm going to run Redline's Water Wetter in the coolant, and also use a leaner mixture of regular coolant for maximum heat transfer

BUT. I'm still worried about my cooling, because there's almost no air flow to the radiator except through the other three radiators...
Maybe I will drill some holes to the bumper anyway 

how much bigger is the passat tdi with a/c radiator comparing to my 1.9td passat?

[TurboJ]

how much bigger is the passat tdi with a/c radiator comparing to my 1.9td passat?

It's actually a Passat B4 1.9 TDI Automatic with A/C radiator.
 
I don't know how it measures to your rad, but it's the biggest there is on the Passat's spare parts list.
It's 10% bigger than the mk2 TD heavy duty radiator.

[TurboJ]

Spending some quality time with the engine after a while.

Test fitting the manifolds, turbo, W/G and the downpipe.


























...then I proceeded to some cutting. Aki's old TwinCarger downpipe required a little re-aligning, so I let the angle grinder sing its song:






On the intake manifold Aki had already ground little notches to allow getting to the valve cover nuts more easily, but the G60 valve cover
required more space still, so I had to cut the manifold down a bit.





I'll make some plugs for the holes out of round pipe to allow room for the bumps in the valve cover where the middle two studs and nuts reside.

[theman53]

The Allis Chalmers orange is dead sexy.

[TurboJ]

The Allis Chalmers orange is dead sexy.

Thanks, mate 

BTW, would you (or anyone of course) have a suggestion for the color of the intake manifold and boost pipes?
There's some black, silver and orange now in the engine compartment, and of course the bay itself is red..
Polished is right out of the question, I do not like shiny parts on an '80s car.

I have black silicone connectors for the boost pipework.

My thinking goes like, black would be cool, but maybe too stealthy - the manifold would be sort of invisible against the black cylinder head
Orange: As the valve cover is orange, adding orange parts directly next to it would be sort of tacky maybe.
Silver: would be cool but maybe a little bright.
Red: Well, no other engine/transmission part in here is red, so that wouldn't be tasteful.

Hmm...

[Gizmoman]

Possibly the color it is now (light grey) but glossy like the rest of the bits.
Nice job!

[justiz00]

Flat white for the parts, or maybe a light blue?

[theman53]

I think a solid color on the rest of the parts is out. As you know too much orange or black next to eachother looks like to much...Although if you wanted the boost pipes and intake to match without adding red into the equation you could tiger stripe the rest orange and black. Then it would stand out even more and match completely without being too much of one color. You could do like a barber shop pole on the boost pipes of orange and black, that would be funny.