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Engine Specific Info and Questions => IDI Engine => Topic started by: golfmk1tdr on January 13, 2015, 11:41:28 am
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BIG TURBOS!!! (vtn? :-[)
AERO MODS!
TRACKDAY VIDEOS!
All things yet to come (hopefully :P)
But first:
Been in love with mk1's since I first drove one when I was about 12...
But somehow people around me never knew how much it meant to me until
I swapped my lovely peugeot 1.6 petrol 306 for rusty slow old brick. ;D (arrived on trailor naturally)
They told me I am insane to even think about making it road legal
and I didn't listen.
They told me it was too old and too slow
and I thought to myself, you wait and you will see.
They told me this things cost time an money
and... they were right. ::)
Took a lot of sacrifice to get here, but after a year long rebiuld
I can now enjoy my car daily. :D
(http://shrani.si/f/3E/Hk/3GkNXv8H/mk1tdr.jpg)
(http://shrani.si/f/3k/4M/2G2pdHXE/dsc0200rep.jpg)
(Photo taken on newyears eve, outside temp. -15 °C :-X )
I have to say I didn't expect so much positive attention on the road,
I had girls wawing at me on motorway, (bit of ashock to see girls like my car 8)(opposed to my gf-s that didn't handle it so well)
I had thumbs up from people I overtook... (really temping not to give them more smoke in return ;D)
But still feel I am not finished.
So when people ask me to do a biuld thread I allways hesitate...
This is no showcar as I did everything myself and I can get bit sloppy/lazy at times.
Also no expensive parts as I can't afford much.
So if I can't show bling wheels and superclean engine bay (though I had some luck parts hoarding 8))
how could I interest people to make this worthwhile?
So I set goals for my car in hope that you lot will appreciate my efforts ;)
205+ kph top speed (to justify my speedo range 8))
-8s 0-100kph acceleration (to smoke gti's ;D)
+100000 km engine life (hopefully :P)
So yes, when finished I am expecting to be able to smoke 16v GTI on motorway and round racetrack,
trick will be not to blow engine trying...
Also if you like nice dyno graphs I am afraid I will have to disapoint you as I plan to do my
aero charts and power numbers using timer, dash, maths and cellphone app's (I believe in grassroots engineering :P)
So-any takers for this thread?
Any support will be much aprecciated since this car is taking it's tool on me as far as familly and friends go...
Feel free to correct any spelling mistakes and the like, I like it when people show my mistakes. (not native speaker)
Ran out of time for explaining current status so I will finish this too-long first post with turbo question:
Is stock VTN 17 right direction to take for daily 150 crank horsepower on 1.6 TD?
Seen one today for sale and I thought-perfect!
Current T3 turbo is just too much lag. HELP! ???
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do you have a boost controller on it? increasing fueling will help to spool the turbo faster, you should be able to beat a stock 16v with a lightly modded 1.6td pretty easily. you could swap a volvo t3 50 trim compressor on to your current t3, im not sure how that effects spool up but it is a much more efficient compressor and flows a lot more air. 52 trim gt2052 is a good turbo, or he200wg
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do you have a boost controller on it? increasing fueling will help to spool the turbo faster, you should be able to beat a stock 16v with a lightly modded 1.6td pretty easily. you could swap a volvo t3 50 trim compressor on to your current t3, im not sure how that effects spool up but it is a much more efficient compressor and flows a lot more air. 52 trim gt2052 is a good turbo, or he200wg
also larger down pipe will help spool up
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CURRENT ENGINE BAY STATUS:
MK2 GTD ENGINE FULLY REBIULD,
METAL HEADGASKET,
NEW STOCK HEADBOLTS (should I worry?)
T3 trouble turbo,
FRONT MOUNTED IVECO TRUCK INTERCOOLER,
6cm NEW EXHAUST,
STOCK TOILET BOWL DOWNPIPE,
CTN GEARBOX ON SELFMADE MOUNTS (5th gear at 5000 rev should be around 230kph 8))
STOCK CTN CLUTCH (holds well enough for now)
EGT (AUBER, very cool stuff for the price), BOOST AND OIL TEMP. GAUGES
also my governor looks like this:
(http://shrani.si/f/1W/Q9/43GRp72v/dsc0035.jpg)
So turbos... When engine was rebiuld I had original T2 turbo rebiuld, I liked it because it spooled instantly.
Also boost-control lever on rear of turbo is very easy to control boost so once I set it to max (which was about 1.5 bar)
car became so fast that I got scared for the engine (I didn't have EGT at the time) so I turned turbo back down to about 1.1 bar.
This lasted about 2 months then turbo started smoking in the engine bay (someone told me heat shield is damaged).
Lucky me I had another turbo around from my friend, T3 turbo...
It has some shaft play (up-down about 0.5mm, no play in-out) but what I fear is this:
(http://shrani.si/f/Q/sI/SckHro8/dsc0043cut.jpg)
You can see it's cracked around wastegate valve.
Could this be the reason why I can only have 0.9 bar with blocked wastegate?
How much boost should I get from this turbo on blocked wastegate?
This is also why I am considering VTN17 turbo, I don't want to go into cost of rebiulding this one
and then have this crack getting bigger.
So if anyone can please help me get this turbo right I will be happy, where should I look?
I will try to presurize intake system today to see if I have leak there.
Also, when we were instaling this turbo I turned wastegate around a bit I was thinking maybe
it can be set like T2 wastegate only from inside-I guess not? ???
What is the function of turning wastegate valve?
Is there any other way to check tor wastegate valve leak or stuck besides having it opened?
Also rabbitjockey, how much boost do you get with stock T3? Where does it spool ful boost, 4000?
I would like to run more boost than I can fuel for low EGT and I don't know if T3 can do that reliably.
Still would love someone to comment on VTN17, I only found info about VTN15 done on 1.6..
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That crack is small in comparison to what I have had and seen. It is a 20+ year old turbo it is not a big deal and not the cause of your loss. You could have a much bigger crack and not effect it much.
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Go for the Holset He200wg turbo it's A very good and fast spooling turbo I had it on my old setup very driveable and good for 170-180 whp With modified IP.
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I don't know to much about these engines but if it was me I'd be worried about going bigger turbo without head stud's. I made that mistake on my 1.9td aaz. I ran a k24 with about 30psi and actually lifted the head off the block due to no head stud's.
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My old setup 173whp got standard Bolts and 35psi no problem (aaz head)
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My old setup 173whp got standard Bolts and 35psi no problem (aaz head)
Did alcaid put your dyno video on youtube? I think it was your car, very nice 8)
Can you tell what mods you did to the engine for 173whp?
Stock 1.9 head? (think not ???)
Airflow work? Injection pump size?
I think 170whp mk1 would be my absolute dream car but right now
holset is too expensive for me, I can't put more than 200€ into turbo right now and
I could get vtn17 garret for that or fix my T3 garret with 360degree bearing hopefully.
But I dont think either of these turbos will give more than 120 whp for long...
I don't know to much about these engines but if it was me I'd be worried about going bigger turbo without head stud's. I made that mistake on my 1.9td aaz. I ran a k24 with about 30psi and actually lifted the head off the block due to no head stud's.
Did you rebiuld your engine and used old bolts?
I used new bolts as they supposed to be only used once...
Hope that was your mistake if not I feel bad for my engine already... :-\
That crack is small in comparison to what I have had and seen. It is a 20+ year old turbo it is not a big deal and not the cause of your loss. You could have a much bigger crack and not effect it much.
What do you think is the cause?
You had some tiny boost leaks (if I remember coorectly u have mk2 jetta right?)
I might have tiny hole in my intercooler (less than 1mm square) do you think I would lose so much to that?
STILL HAVING TROUBLE BIULDING BOOST. :'(
I tested if I have intake manifold leak but I couldn't get pressure to stay in manifold with blocked
tubing, is air leaking on valves normally or should it hold pressure?
What is most common reason for bad boost on IDI?
Intercooler/boost tube leak?
Could I have bent valves? (hoope not)
Or is turbo just too far gone? I believe it should still charge more than 1bar since it's not grinding vanes or anything...
I don't have much fun driving the car anymore since I get smoke instead of power making me rather depressed lately :-[
Sorry my nagging but I really could use some pointers as I feel I am looking at wrong stuff all the time
and staring at engine bay isn't fixing much but I can't disssasemble daily driver to diagnose.
Any tips on diagnosing my lack of boost would be much aprecciated... :)
I was even considering to tell my grandma to blow cigarette smoke into boost tubing as I don't smoke...
But I don't think her lungs are up to that ::)
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Go for the Holset He200wg turbo it's A very good and fast spooling turbo I had it on my old setup very driveable and good for 170-180 whp With modified IP.
The Holset is a fantastic turbo. I helped my son put one on his mk2 jetta. It spools quickly to 32-33 psi, even at our elevation (~6000 ft), with egt rarely exceeding 1100 deg F. He consistently averages 42-44 mpg in city driving. A friend of his has a 2010-ish WRX, and after a 2nd-3rd gear pull, the Jetta is within a car length (i.e. front bumper next to the WRX's rear wheel) at the top of third gear. It's impressively fast, particularly with no passengers. He's saving his money for an AAZ head.
Not to change the subject, but we just picked up a sweet '79 rabbit diesel that has a newer 1.6 na and 12mm head bolts. This one will be a project with my 15-yr-old daughter, who gets her license this summer. I told her, "Hey, I don't think we'll be able to get the euro bumpers for a while -- they're pretty expensive." She replied, "That's okay -- I think I'd rather get a turbo first." :) I'll probably end up getting another Holset, even though they're a little more expensive than the OEM options.
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I did use new head bolts but they are stretch bolts and didn't agree with high boost for me. It was my own fault I should have ran head stud's. High egts may factor in to as I didn't have an egt gauge at the time
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My old setup 173whp got standard Bolts and 35psi no problem (aaz head)
Did alcaid put your dyno video on youtube? I think it was your car, very nice 8)
Can you tell what mods you did to the engine for 173whp?
Stock 1.9 head? (think not ???)
Airflow work? Injection pump size?
I think 170whp mk1 would be my absolute dream car but right now
holset is too expensive for me, I can't put more than 200€ into turbo right now and
I could get vtn17 garret for that or fix my T3 garret with 360degree bearing hopefully.
But I dont think either of these turbos will give more than 120 whp for long...
Same car yes. If my memory is correct, it was a completely stock 1.6 bottom with a stock AAZ head. 11mm pump by dieselmeken, and a older Holset HE211W. The newer HE200WG is capable for even more.
The HE200WG is worth every penny. I have one on my MK4. MK1 diesel did most of the custom work on my car
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lifting heads is an issue with running too much boost with too small and inefficient of a turbo, like a k24
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If you're investigating a VNT 17, after I blew-up my 15, that's what I bought for my 96 1.6 td. I had a bit of problem trying to reuse the oil pan fitting for the drain. I didn't like it so I drilled the pan just under the block in center of pan and drain it there. The other thing with any new vw turbo on older cars the engine mount on pass side has to be replaced, even if you're thinking of a 2052 or silmilar; that is in a MK2 or Mk3. Not sure how it will fit in a MK1. Might be fine??
As far as the turbo goes it's fantastic. I don't drive it super hard, usually stay under 3500 rpm or so. I've got it set by about 1750 or so rpm I can be at full boost (I set mine to max out at about 18-20 psi). I've had it for 3 year now -about 45000 km no issues. Instant gratification because the 1.6 likes to rev so well.
I have a 99 tdi also in a golf, it doesn't pickup as fast in the lower revs as the 1.6td. With a 2052 turbo once over about 2200 rpm the tdi is much, much quicker. My .02$ the vnt on a 1.6 is better than the 2052. It fits the 1.9 engine much better.
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If you're investigating a VNT 17, after I blew-up my 15, that's what I bought for my 96 1.6 td. I had a bit of problem trying to reuse the oil pan fitting for the drain. I didn't like it so I drilled the pan just under the block in center of pan and drain it there. The other thing with any new vw turbo on older cars the engine mount on pass side has to be replaced, even if you're thinking of a 2052 or silmilar; that is in a MK2 or Mk3. Not sure how it will fit in a MK1. Might be fine??
As far as the turbo goes it's fantastic. I don't drive it super hard, usually stay under 3500 rpm or so. I've got it set by about 1750 or so rpm I can be at full boost (I set mine to max out at about 18-20 psi). I've had it for 3 year now -about 45000 km no issues. Instant gratification because the 1.6 likes to rev so well.
I have a 99 tdi also in a golf, it doesn't pickup as fast in the lower revs as the 1.6td. With a 2052 turbo once over about 2200 rpm the tdi is much, much quicker. My .02$ the vnt on a 1.6 is better than the 2052. It fits the 1.9 engine much better.
Wow finally someone with info on 17vtn :D
20 psi under 2000rpm sounds too good to be true, you sure you aren't exagerating a bit?
How do you control vanes? Pedal connected? Electronics?
Did you use stock exaust manifold with adapter plate? VTN17 has 3 bolts for manifold right?
Can you share a photo maybe?
I did kind of decide to go with holset turbo but still very interested into VTN so please share, any info is great..
Also engine mount in mk1 is different so that should be no problem...
lifting heads is an issue with running too much boost with too small and inefficient of a turbo, like a k24
So to much backpressure is main concern? I am reconecting BOV A.S.A.P hearing you say that :-X
My old setup 173whp got standard Bolts and 35psi no problem (aaz head)
Did alcaid put your dyno video on youtube? I think it was your car, very nice 8)
Can you tell what mods you did to the engine for 173whp?
Stock 1.9 head? (think not ???)
Airflow work? Injection pump size?
I think 170whp mk1 would be my absolute dream car but right now
holset is too expensive for me, I can't put more than 200€ into turbo right now and
I could get vtn17 garret for that or fix my T3 garret with 360degree bearing hopefully.
But I dont think either of these turbos will give more than 120 whp for long...
Same car yes. If my memory is correct, it was a completely stock 1.6 bottom with a stock AAZ head. 11mm pump by dieselmeken, and a older Holset HE211W. The newer HE200WG is capable for even more.
The HE200WG is worth every penny. I have one on my MK4. MK1 diesel did most of the custom work on my car
How much power is that on mk4, did you dyno?
I did use new head bolts but they are stretch bolts and didn't agree with high boost for me. It was my own fault I should have ran head stud's. High egts may factor in to as I didn't have an egt gauge at the time
What was the damage after that? Anything besides head gasket leak?
Thinking about 1.9 AAZ head
Read people saying that AAZ on 1.6 doesn't work, can anyone explain why some have issues?
Thank you all for contributing 8)
This forum has so many posts now it's time consuming to find info I want, this is much better :)
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The damage was more then we thought. Originally I just sent it to get planed and the pre combustion chambers replaced. But since then the car never worked right. I'm putting a brand new 0km head on it this time.
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keep the bov disabled, when that thing opens it creates a major boost leak which can over spin the turbo and destroy it, its better to over boost a little(20psi) than to over spin it that hard.
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Regarding boost leaks... We had a couple of intake manifold bolts start to loosen a while back, and a short section of the intake manifold gasket blew out, creating about a 5 psi boost leak. Peak EGT soared from around 1100F to the low 1500s :o Another reason to have an EGT gauge.
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How much power is that on mk4, did you dyno?
According to Alcaid the turbo can deliver ~260 crank hp on a TDI. I'm running stock internals and head, so i'm not planing to take out that much.
I have not dynoed the car, the tune is not finished and the preferred dyno in this area is closed during the Winter. I get disappointed if it does not have over 200 cank hp and hoping for about 220. Combined with 4Motion, the car is really fun :)
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Regarding boost leaks... We had a couple of intake manifold bolts start to loosen a while back, and a short section of the intake manifold gasket blew out, creating about a 5 psi boost leak. Peak EGT soared from around 1100F to the low 1500s :o Another reason to have an EGT gauge.
Could you hear hissing sound when biulding boost with that leak?
I cant hear anthing thats the reason I suspect wastegate leak rather than intake/head gasket leak.
Also gasket are all new vw :-\ If it leaks that was money wasted :-[
How much power is that on mk4, did you dyno?
According to Alcaid the turbo can deliver ~260 crank hp on a TDI. I'm running stock internals and head, so i'm not planing to take out that much.
I have not dynoed the car, the tune is not finished and the preferred dyno in this area is closed during the Winter. I get disappointed if it does not have over 200 cank hp and hoping for about 220. Combined with 4Motion, the car is really fun :)
No need for dyno if you ask me, just measure straight road to 1/4 mile and do standing start run both ways...
Look for speed exactly when you pass 1/4 mile mark.
Speed on the end of q-mile run in relation to car weight is best homemade dyno,should be pretty acurate.
For everyone interested into free dyno...
http://www.turbobricks.com/resources.php?content=quartermiledyno (http://www.turbobricks.com/resources.php?content=quartermiledyno)
current status
Car still not boostin as it should, so I am saving for holset turbo already in contact with alcaid.
Funny enaugh I got twice the pay this month (accountants accident, almost had heart attack)
Very tempted to just order turbo, but I wont get any pay next month becose of this so I am playing it safe,
hopefully selling some rims tommorow then I will think about ordering again.
Car is just daily driver right now, don't have garage to work now so with snow outside I don't really feel like opening the turbo.
Hopefully a friend will let me use his shop but he is 2 hour drive away so it only makes sense if I do it on weekend.
So with Holset in mind (still excited just to think about it :P) now comes the issue of exhaust manifold.
(http://thumbs4.ebaystatic.com/d/l225/m/mqWWoYffYYP4En0Z_eHx14A.jpg)
This is picture I searched for on ebay with recomendation from alcaid, but I feel with shipping cost's included it's too expensive,
I would rather search for used one.
If anyone can say which cars have suitable exhaust manifold for 1.6 TD for mk1 GOLF so I wont have fitment issues, please say it.
Will do research right now still here might be faster.
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Could you hear hissing sound when biulding boost with that leak?
I cant hear anthing thats the reason I suspect wastegate leak rather than intake/head gasket leak.
Also gasket are all new vw :-\ If it leaks that was money wasted :-[
No hissing; just lower boost than expected and high EGT. I used a spray bottle with soapy water to find the leak.
Regarding the manifold, this is the one I got. (http://www.ebay.com/itm/380395953632?item=380395953632&viewitem=&sspagename=ADME:L:OC:US:3160&vxp=mtr) Looks like it's currently $78 w/ free shipping in the U.S.
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Could you hear hissing sound when biulding boost with that leak?
I cant hear anthing thats the reason I suspect wastegate leak rather than intake/head gasket leak.
Also gasket are all new vw :-\ If it leaks that was money wasted :-[
No hissing; just lower boost than expected and high EGT. I used a spray bottle with soapy water to find the leak.
Regarding the manifold, this is the one I got. (http://www.ebay.com/itm/380395953632?item=380395953632&viewitem=&sspagename=ADME:L:OC:US:3160&vxp=mtr) Looks like it's currently $78 w/ free shipping in the U.S.
How did you pressurize the intake to check for bubbles? Revved the engine?
Also I am from europe, so shippiung included that's over 160 bucks... Thank you anyway. That remids me I should update my user info.
Do you have holset on 1.6D engine block? Or is it TD block? Just curious, I would have thought stock engine cant handle such boost safely...
EDIT:
This looks to be the same manifonld, but here it's listed for VW Phateon ???
Can anyone confirm Phateon manifold fits our heads? Interesting... VW legos for adults ;D
http://www.andysautosport.com/products/cx_racing__MF-VW-8V-T25-CAST.html (http://www.andysautosport.com/products/cx_racing__MF-VW-8V-T25-CAST.html)
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How did you pressurize the intake to check for bubbles? Revved the engine?
Also I am from europe, so shippiung included that's over 160 bucks... Thank you anyway. That remids me I should update my user info.
Do you have holset on 1.6D engine block? Or is it TD block? Just curious, I would have thought stock engine cant handle such boost safely...
Yeah, we just revved the engine in neutral.
Regarding the confusion on shipping...I just assumed you were in the U.S. -- sorry about that!
The engine is a 1.6d, not a 1.6td. Someone correct me if I'm wrong, but I believe the biggest difference is the lack of oil squirters. Structurally, all the components are just as strong. With no oil squirters, I have to keep the peak EGT about 150F lower, which isn't a problem with the Holset at high boost. I'll be going to a MLS head gasket and ARP head studs after porting the head, but so far, the stock stretch bolts and HG and holding up fine.
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The damage was more then we thought. Originally I just sent it to get planed and the pre combustion chambers replaced. But since then the car never worked right. I'm putting a brand new 0km head on it this time.
Did turbo survive??
What was the cost of chambers, expensive? Didn't know you can change them.
How did you pressurize the intake to check for bubbles? Revved the engine?
Also I am from europe, so shippiung included that's over 160 bucks... Thank you anyway. That remids me I should update my user info.
Do you have holset on 1.6D engine block? Or is it TD block? Just curious, I would have thought stock engine cant handle such boost safely...
Yeah, we just revved the engine in neutral.
Regarding the confusion on shipping...I just assumed you were in the U.S. -- sorry about that!
The engine is a 1.6d, not a 1.6td. Someone correct me if I'm wrong, but I believe the biggest difference is the lack of oil squirters. Structurally, all the components are just as strong. With no oil squirters, I have to keep the peak EGT about 150F lower, which isn't a problem with the Holset at high boost. I'll be going to a MLS head gasket and ARP head studs after porting the head, but so far, the stock stretch bolts and HG and holding up fine.
Wow you are pushing some serious power through stock engine then, looks like I was smart to keep my stock block for spare :)
TD head supposed to have cooled exhaust valves but I don't think they matter much.
What kind of boost you pushing in with stock gasket?
UPDATE (is this right place in the forum? or should I do another thread in userers ride wall?)
Bought bigger brakes for the front of the car today, I think it is smart when planing 200+ top speed and trackdays... :P
Also hoping to order Holset turbo next week from alcaid if I manage to sell some project car over weekend, can't wait.
Also any way I put it, I can't justify buying exhaust manifold right now.
With postage it's about 150 bucks and then new gaskets and drilling EGT sensor in again... That also translates to waiting another month for paycheck, really annoying with broken turbo on daily :-\ :( :-[ :'(
I am thinking of doing this with adapter plate, I am willing to sacrifice bit of power as long as it's not reliability issue... Anyone did it this way?
I will probably get AAZ head and correct manifold,have it flowed/ported in summer+possibly custom intake long runner manifold, but I just want to put this turbo on ASAP. :)
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The turbo did survive but I decided to go with the holset and the block was also cracked and broken piston which I recently found out. So I have no idea what kind of power this holset will realease but this spring I will
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I am thinking of doing this with adapter plate, I am willing to sacrifice bit of power as long as it's not reliability issue... Anyone did it this way?
I will probably get AAZ head and correct manifold,have it flowed/ported in summer+possibly custom intake long runner manifold, but I just want to put this turbo on ASAP. :)
I originally did a dry fit with the Holset and stock 1.6TD exhaust manifold to see if an adapter plate would work. I'm running a gasser intake manifold, so there wasn't any room for the turbo with the exhaust manifold installed normally. With the exhaust manifold inverted, the Holset and rear engine mount were trying to occupy the same space, so that didn't work either.
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On my MK4 I have the stock manifold from the european AGR engine (same as ALH, but with a factory wastgate turbo) with a T25 flange welded on. This way the turbo hangs under the manifold. I think this will work on a MK1. It should be possible to find a used one
(https://dl.dropboxusercontent.com/u/1499906/Mk4%20TDI%204motion/Photo%2007.04.14%2021%2023%2024.jpg)
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About time to get thist thread back closer to first page :P
Much has been going on around my car, unfortunately nothing good about the engine :-\
--Instaled bigger brakes from Opel, so car now hangs me on safety belt when I slam the pedal :)
--Fixed gearbox leaks so after long time there are no puddles when park
--Ordered and paid Holset turbo from Alcaid, so expecting to get it in 2 weeks time
--Lowered car back to normal height from winter jeep mode (just right stance but still good ride)
On my MK4 I have the stock manifold from the european AGR engine (same as ALH, but with a factory wastgate turbo) with a T25 flange welded on. This way the turbo hangs under the manifold. I think this will work on a MK1. It should be possible to find a used one
(https://dl.dropboxusercontent.com/u/1499906/Mk4%20TDI%204motion/Photo%2007.04.14%2021%2023%2024.jpg)
Thank you for this pic, you helped me to decide on buying new manifold ;D
To think I would hang my precious new turbo to cast iron weld gave me chills,
so I am also purchasing exaust manifold-had some good offers but still waiting for some replies.
Did you give it to pro to weld it or was that done at home?
I know it's not easy to do properly so I quess it was rather expensive if pro did it...
BIG NEWS:
I 've been offered NEW 1.9 aaz head ;D 8)
Only problem is that its naked head, no cam, no valves, no nothing :-\
So can you tell me what parts from my 1.6 TD head fit to 1.9?
I will look into frankenhead mods if nobody feels like repeating,
but I need to know how huch stuff do I need to buy to make 1.9 head work.
Valves are different, correct?
What about valve guides and cam? Can I use 1.6 cam and sprocket?
I really hope injectors are the same :-\
I hope anyone tells me here so I don't have to make new thread .
Also tonight was fun, had a tuned Renault in my rearwiev, too baad my turbo is broken or I would leave him mile behind.
Need more poweeeeer! (had to say it since Jezza doesn't anymore ;D )
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Thank you for this pic, you helped me to decide on buying new manifold ;D
To think I would hang my precious new turbo to cast iron weld gave me chills,
so I am also purchasing exaust manifold-had some good offers but still waiting for some replies.
Did you give it to pro to weld it or was that done at home?
I know it's not easy to do properly so I quess it was rather expensive if pro did it...
The weld was done by a friend of Alcaid. I don't think he's a pro welder, but he was the most experienced present when we put on the turbo. The car has been my daily for one year now without any problems
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(http://shrani.si/t/2N/Vs/162Ulhas/dsc0031.jpg) (http://shrani.si/?2N/Vs/162Ulhas/dsc0031.jpg)
Now the real tunning begins to see how much can be done on stock 1.6 GTD pump :P
Currently set at about 1.1 bar since the smoke is gone, probably modifying max fuel screw today if I have nothing else to do.
I have to figure out how to bring idle revolutions back down, I will try to rotate lever for a bit so it doesn't hit idle screw.
Will stay under 1.5 bar since I only have (new) stock headbolts, I think it should still be plenty fun.
Really annoyed by leaking valve cover gasket, I have 1.9 td rubber gasket under here but it still leaks from rear side by the pulley >:(
I have to get my better set of tires on, these are just spinning stupid especially on wet road ::)
Will try to do some quarter mile runs this week so I can estimate my power, I can't tell how much improvement it is since power delivery
with this turbo is so constant it doesn't really ''hit'' it just keeps pulling.
Also public thank you to Alcaid, he was cool and professional, hopefully I didn't annoy him too much with all my questions.
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Also public thank you to Alcaid, he was cool and professional, hopefully I didn't annoy him too much with all my questions.
Haven't been on this forum for a while, nice to see it's up and running and good luck with tuning it. You really need a built pump now ;)
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Finally rainless day, woke up in the morning first thing on my mind: Great I should so some quarter mile runs
So I ran google maps, searched for closest straight road.
Used some online measurning application that is used to measure parcels (I had to learn using that to measure my dad's farm for goverment)
Learned that difference between 2 intersections on that road is 390 meters, close enaugh to 402 m qmile-perfect :D
also cops can't give me *** because ''I just drove onto the road''
Also, nice thing there was flood just under road so I could see road is nice and level ;D
Drove the straight normally whole lenght to check for case of cops in the bushes, all clear :P
So drive around to intersecton, wait till traffic clears, join the road, stop when I am pointed straight, floor the pedal :P
first gear easy to desrease wheel spin, second gear still wheelspining a bit, then finally takeoff to 130 kph at the intersection :P
second run pointing other way, managing wheel spin bit better, I see 140 kph at intersection, I was a bit suprised so I tried again 2 times,
now running 140 both ways very satisfied with result I headed home.
140 is about 87 mph, I reduced it to 83 so I can be sure I am talking minimal possible number (should be more since speedo is almost spot on when GPS checking on the highway and radar speed info traps)
Car weighted 840 kg on weighing bridge last november, with me in it should be around 920 but I will make it 900 kg so I have worst case scenario (engine BHP beeing the focus here)
If I calculate with these numbers here http://www.torquestats.com/modified/index.php?pid=calculator&action=calculate_times&drive=FWD&bhp=115&weight=900&submit=Calculate (http://www.torquestats.com/modified/index.php?pid=calculator&action=calculate_times&drive=FWD&bhp=115&weight=900&submit=Calculate)
I estimate my engine to have over 115 BHP right now ;D
Not bad for start I think, really happy with it considering that measurment is underestimated on speed and weight, also few meters short of quarter mile.
Any way I put it I should have Mk1 GTI smoking car right now, around 8 second 0-100kph (0-60mph).
Still can't help feeling car is not fast enaugh, I am considering glassfibre bonnet and widened GF arches some guy nearby is selling,
also I will make boost pin at work and GOV mod solid stainless steel shim (it's shimmed by few nuts, not enaugh I feel GOV kicking in in high rev)
Also need head studs, currently at 1.3 bar with some boost leaks, I don't think this head will survive but I have been offered new head so I am not scared but still I hope I get head studs before head lifts :-[
Also public thank you to Alcaid, he was cool and professional, hopefully I didn't annoy him too much with all my questions.
Haven't been on this forum for a while, nice to see it's up and running and good luck with tuning it. You really need a built pump now ;)
It seems I am about to get promoted at work, if that really hapens Dieselmeken is certainly getting my mails right after ;)
Still I believe the limit of stock 8 mm pump is higher and I will try to find if before crazy power happens ;D
off to watch f1 monaco //
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Last week I was instaling oil pressure sensor and I noticed my fuel pedal wire is loose on the pump, so I tightened it up and then I put a brick to pedal to see if it goes all way up on the pump. I was shocked when I see the lever on the pump has only gone slightly more than half way :o
I was driving all this time like this, real smart me. so imidiately test drive was in order, suddelny car is smoking again and i am afraid of using full throttle ;D I did about 145 kmh quarter mile with car slightly loaded, it was just one really so no science there but difference is noticable.
If that time is repeatable it means above 130 bhp which it just nuts ;D
But it wont be repeatable anytime soon because driving to the meet yesterday I went crazy on motorway and at over 180 kph there was noise under bonnet, whistling and EGT alarm went off.
I believe my junkyard intercooler finally gave it's life.So I plumbed piping without any intercooler and I was shocked to see how bad the car is without intercooler, it boost fine but doesn't have any power and anytime I go near fuel pedal EGT's go into alarm zone, engine is trying to overheat on me, I swear NA engine would overtake me right now :-X
It sems I just can't run without intercooler on turbo of this size.
So right now I am searching what IC size is best for my turbo/engine, I am trying to do this once and do it right, especialy after seeing how much difference it makes.Deffinately air to air FMIC.
Can anyone tell me what IC size I am looking for? I have seen quick estimate of 3L/100hp, that would mean my should be around 6L is that correct? Is that maesured including cooling fines or just the air that can go in?
Also I am worried about new IC exploding, I am not sure all IC's are made to handle 30+ psi, or should they be fine?
I am working on it right now but still I would be thankful to all HW200 holset owners if they say what they are runinng/how they calcualated that.
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So the ball is rolling again 8)
I 've just put down payment for ARP studs :) after I realized they also fit TDI engines (3 TDi engines running in family right now) and they are reusable that decision was easy really.
I wasn't really planing on this because being a regular student and working afternoon job supporting myself, my goal for this year has been lowered to just get the car running again on minimum boost for minimum cost and maximum reliability.
After having low oil pressure problem on my first fully build engine (probably intermediate shaft problem, internally engine looks fine despite running full trackday on 1 bar oil pressure at 4000 rpm) and blowing second engine headgasket on test run (I just put holset turbo on regular 1.6 D and hoped for the best... No can't do on ***ty stock headgasket ).
Then I took the head of first engine (td) and put it on 1.6 stock bottom end (headgasket put a crack on it's head) and then I had some fun with this combo for a while ( sub 8 second 0-100 was measured with 100 kg friend in the car, another confirmation I had around 130 hp on stock slightly modded IP)
Unfortunately that lasted only for about a month when something exploded under the bonnet at about 190 km/h while heading to a drag race. In rush to overtake some snob BMW driver who refused to let me by on motorway I let EGT's climb too high, probably destroying headgasket in the process (didn't even bother to check, don't have much time to mess around the car). After that I was pretty much done with the car for a while, I just didn't have the means to rebuild it again and I was disappointed with myself for destroying my engines so many times in such little time. It was time to rethink a bit.
I was toying with idea of 1.9 TDi that is resting in tired old audi I 've somehow ended up with after my father bought it. It's tuned to about 140 hp and it's basically mine, I also found a guy who could make it work with electronics, he would even install cruise control (which is great in Audi, I used it a lot).
Still it just didn't feel right. TDi's just don't feel good for spirited driving, I 've driven the lot of them from 2.5 I5 or v6 to stock 90 hp or 140 chiped ones... It's great engine for hauling stuff about while using very little fuel (heavy old chipped audi still managed under 5 l/100km )
But it just doesn't feel like fast engine with it's low redline and low down torque.
So I heard about some guy half an hour away from me who is hoarding and selling old VW engines. After quick phone call it was clear I had to see his shop ASAP.
Long story short, I bought from him running 1.6 eco TD, 1.9 AAZ head in perfect condition and 1.9 D inlet manifold, and he threw in another IP pump so I have extra one to play with and diesel starter motor for 02a gearbox to replace my small petrol one.
Then I ran out of time and money, until three days ago father reminded me that my winter car's registration expires in few days. I told him I will get it ready for inspection, but next day I've fallen sick (which I still am, hence time to write this :( ) .
So I was talking to my best bud about the situation and he was like: wtf didn't you say you will build your new fancy engine by spring, why you losing time and money over winter car?
I told him that even if I had time to build it moneys just don't add up, I need gaskets and studs and I will have to weld on some extra stainless tubing on the turbo and whole bunch of stuff and that ain't cheap.
Then he said fck that I want to see this thing roll, tell me how much money do you need you will return it in summer.
Just get that thing on the road before winter ends.
So here I am now thinking about all stuff needed done to build my dream engine:
200wg holset
aaz head
ARP headstuds
1.6 td bottom end
lightened 02a flywheel (in stock that porker is heavy as F )
1.9 D manifold (long, equal lenght runners, sweet thing)
big iveco intercooler
big water radiator
1.9 TD 3 notch headgasket ( I think slight CR loss is outweighed by larger valve/piston clearances)
From this list I am only missing the studs and flywheel, but there is a lot of fabrication for the little time I have to put all this together...
GOV modded stock 9mm pump for now, I can replace that anytime with my tools anyway. Will try to put bigger plunger to one of my spare ones if I manage. It will be interesting to see how same pump (fuel) performs on better intake and bigger valves.
Also picked up some pretty wheels just before last explosion and found cheap source of semislicks, so if all goes well I should be hitting some fantastic track days in two months time...
Wheels: (my third ATS set I don't even like ATS lol they just fit the car)
(http://www.volksforum.com/albums/files/2/9/8/atstype5.jpg)
Tires: (tested these on trackday, day and night difference vs. regular street tires, still cheaper than most street tires)
(http://i45.servimg.com/u/f45/11/55/02/34/img_9710.jpg)
Manifold: (Holset will be tight fit under this but with spacer and smart fitment should be possible)
(http://i650.photobucket.com/albums/uu221/mrki_os/DSC01740.jpg)
That's pretty much all I remember to say right now, feeling dizzy again so I am heading back to bed.
I realize most of this was discussed and tried before, so any comment's by more knowledgeable members are welcome...