Evolution of my Sooty - with Dynos

[Gigitt]

Here is my Sooty.

It is a 1996 Golf Mk3 TDI, 1Z engine, 1.9 lt

It has been slowly getting mods over the years.

I have had it Dyno'd 4 times now: Stock, Initial Mods, Mufflerectomy, and on the weekend Intake Manifold.

Stock vs initial Mods: PP520 injector Nozzles, Upsolute Stage 2 Chip Tune, Oil Aitr separator Catch Can.


Mufflerectomy: removed the rear suitcase muffler and rear tailpipe muffler and replaced with 2.5in Stainless Pipe (Stock DP and Cat in place)


Intake Manifold: PD130, Allard ERG Pipe and EGR delete. (also had an upgraded cluch put in and gearbox rebuilt - original clutch was starting to slip at 204,xxx km )


Comparing the Mods...


As you can see there were substantial improvements from stock (43.7kW) to Initial modes (67.9kW), then a supprising large 12.1kW improvement just with a mufflerectomy (80kW).

After installing the PD130 intake, the gains as (not) seen on the Dyno are debateable - I say this as on the road it is a differnet beast.
The PD130 (PD150) intake allows more air to reach/flow into the outer cilinders... just look at my old stock intake (on right) vs the PD130 intake (on left):


So what did the PD130 intake do for me when on the road...
- well the engine is much smoother reving and at idle.
- the car blows next to no smoke now when I plant to gogo pedal. There is only a little puff as the pipes get cleaned and that is it... I now don't leave a trailing smoke cloud.

Now the thinking is less smoke = more fuel is being burnt which should mean more power... and hence why the Dyno results are debatable with a lower score (75.1 this time vs 80 last time) - but then alot of people saw a lower result this day, but not as bad as last year where cars were down 15-20kW and on the weekend only 5kW with no changes in mods.

Here is my latest Dyno Run video:
YouTube - Sooty - VW Golf Mk3 TDI 1.9 1Z - 75.1kW 296.8Nm ATW Dyno Run

Now my other observations...
The Engine does not like running on the Dyno with the Boostvalve.com as the boost controller... but it is perfectly fine on the road! My first Dyno run plot was horrible and it was the boost valve releasing way too early as the revs rose - even though it is set to 17.5 PSI, the ECU did not like what was going on (you can see it in the video)... The operator said boost just died half way into the run and the engine kept going until he took his foot off the pedal... so I switched the boost control over to N75 with Boostvlave spike control and got 75.1Kw and boost was fine throughout the next 2 runs. Toreque is still up there as last Dyno.

The Dyno Operator said running on the Dyno is quite differnet than on the road, the Dyno puts a very different load onto the engine than if you were blasting through the revs on the road.

So.. What is next!

I have done these mod as they are cheap. I probably should get a custom tune.

A bigger turbo is always the best option and would be the next hardware mod for power - and to do it right: new exhaust header, new downpipe, front mount intercooler and pipe work, 11/12mm fuel pump head... and then at the same time I have to consider that the 1Z has weak internals and I should probably put in sronger Rods and Pistons... Well I don't have $10k to do all this.

I am pretty happy with what the car is doing now.