aaz turbo option

[Gizmoman]

Very sweet!

I love my Holset HE 200, just wish it spooled quicker than 2K for my 5,000 lb van with tall tires (not the turbo's fault),
Maybe I need to turn up the fuel

[jmaddocks]

Looking good nice to hear it is up and running

Thanks, Petter!  We are very, very happy with the turbo.  It was probably a lot more work than an OEM setup, but the results have exceeded our expectations by far.  My goal was to build something that would keep up with modern traffic, but the car is actually...dare I say... *fast* now.  During yesterday's shakedown run of our new clutch, we were out on a little country road, and a Mk3 GTI caught up to us and got right on our rear bumper.  We slowed down and did a couple of accelerations back to the speed limit.  The GTI faded away pretty quickly each time.  Okay, it was an 8V GTI, but still...

Very sweet!

I love my Holset HE 200, just wish it spooled quicker than 2K for my 5,000 lb van with tall tires (not the turbo's fault),
Maybe I need to turn up the fuel

Thanks!  Yeah, thankfully it seems to be a great match for our ~2200 lb Jetta.  It spools reasonable quickly (even at altitude), much quicker than the T3/T4 in my 16vt corrado, but I'd call it more of a horsepower setup than a torque setup.  The midrange is impressive, but it keeps pulling to redline.  Can't wait to get an AAZ head on it...

At first, we were consistently maintaining about 21 psi, but turning up the fuel simply increased our EGTs.  I said, "well, I guess that's it".  Then I noticed there was a little bit of black smoke under boost, so I disconnected the wastegate.  Voila, 24.5 psi with no smoke, and EGTs spiking below 1400 F.  I subsequently turned up the fuel a tad, and we're hitting 25-25.5 psi, but occasionally spiking EGT to the high 1400s, so I can't go any higher (EGTs stay in the "safe" range if we shift earlier).  Next step will probably be water/alcohol injection to recover some EGT margin, along with ARP studs and a metal HG.  Here are the highlights of our current setup:

- Mk2 Jetta 1.6d
- HE200WG
- Cast 8V T25 exhaust manifold, cleaned up and gasket matched.
- G60 intake manifold, also gasket matched
- FMIC
- 2.5" turbo-back exhaust, techtonics over-axle w/ resonator, no rear muffler
- Auber instruments dual-channel gauge w/ EGT and boost
- 9.5 lb flywheel w/ 16V PP
- NA LDA pump, governor mod, modified for boost input, trying to source a stiffer aneroid spring...

This is my first experience with diesels.  I have to say it's been a lot of fun.   

[Alcaid]

Both of you need bigger pumps, you are propably running your 9mm pumps with looong injection duration giving you higher EGT and PCP than needed. With enough fuel you really need the wastegate hooked up to keep the boost at the level you want it to stay at.

[theman53]

Yeah I think an 11mm pump is going to go on mine. I see maybe 800f and I am controlling idle with the fuel screw, but I have a 10mm head

[Gizmoman]

I'm not a pump expert and have no desire to change mine.
Just for the record though, mine is a 1.6 pump tuned by Giles. I also purchased four new injectors from him at the same time. I asked him to get in the 120-150 HP range and he said, OK.

I'm not getting any smoke I can see. Would turning in the fuel screw help with lower end?
(sorry - don't mean to derail this post)

[Alcaid]

More fuel = faster spool

[jmaddocks]

Both of you need bigger pumps, you are propably running your 9mm pumps with looong injection duration giving you higher EGT and PCP than needed. With enough fuel you really need the wastegate hooked up to keep the boost at the level you want it to stay at.

I never would have imagined a bigger pump would help w/ EGT, but that makes sense.

[Gizmoman]

More fuel = faster spool

Thanks, I'll give it a try

[mark3kid]

Hey guys. Anyone know what to use for the bolt for the feed line? Does the adapter out of the stock vw turbo work?

[Alcaid]

Use a M10x1.25 banjo bolt or use an M10x1.25 to AN4 adapter with a copper washer to seal

[jmaddocks]

Use a M10x1.25 banjo bolt or use an M10x1.25 to AN4 adapter with a copper washer to seal

x2.  I originally bought an alloy M10x1.25 AN4 adapter off ebay, but had some concerns about its longevity in a harsh temperature/vibration environment.  Ended up using one of these with a copper washer:

http://www.summitracing.com/parts/EAR-592045ERL

[mark3kid]

im hopping to try and get that fiting somewhere local i dont feel like waiting a couple weeks for shipping.

so i am going to be bolting the turbo in this week hopefully and soon get it running 
we made our bracket and got everything mounted

[mark3kid]

Hey guys
So car is running and it works good but I do not like the cam as it won't start easily with it in. I'm wondering what the waste gate is set at. I currently only make about 18psi and it pulls hard but my egts are crazy high. But i do have a bad leak on cylinder one between the head and manifold so gopeffuly with the stock cam and the turbo spooling off and 4 cylinders the egts will drop. I'm glad the site is back online

[Alcaid]

Fix that leak and get that boost up, more boost lowers EGT.

[Gizmoman]

FWIW, I have a 1.6 pump with a giles tune.

I went on a long trip a month back and tuned it as I went (tightening the gate rod).
I ended up wiring it shut with mechanics wire. It's great now and I can hit 20 at WOT for a short hit.

Egt's are quite a bit lower while freeway driving but I can still reach 1140 if I want to.

No expert on turbos but my guess is I'm not inputting enough fuel or should I say, at the right time.

I'd enjoy fiddling with it if I had time, but I don't and it meets my needs at the moment.