The mk3 1.9L TD power-quest

**gldgti** · 18-04-2011, 05:18 PM

Thanks Greg - I used to have the gauges way down in the console below the ash tray, so I think its safer now as instead of looking completely away from the road I only have to look a little bit away

.....

Your comments on the provent catchings is good info. I need to modify the breather hose from the block to the head anyway, so I think I will simply put provision there to plumb the oil back into the case. Do you just have a little non-return valve on it?

This has inspired me to get into the manifold work once again, I might revise my design so that I can make it out of stainless, mainly because it will be a lot easier for me to do that than make it from alluminium. Apart from being busy, its just extra effort to try and source it whereas stainless is easy for me to get hold of (and weld!)

**Greg Roles** · 18-04-2011, 08:18 PM

I used the Mann PCV valve. I couldn't find one that sealed as well, bought two off ebay USA before I bit the bullet and just got the Mann one, and I can confirm it is very low pressure and seals ABSOLUTELY air tight, but it's $22 retail which is a bit steep. Obviously cheaper for diesel tinkerers, but yeah if you can find a low pressure well sealing one, I'd love to hear about it!

You have motivated ME to get my plumbing in, and get back to making some real progress now that I am definately keeping the thing, and there's no more warranty to worry about - not that I had much since that first dremel touch.

**Gigitt** · 20-04-2011, 01:13 AM

Jarred... I'm the Marko with the TDI.

I just posted a thread Evolution of my Sooty - with Dynos.

There are Dyno plots showing results from Stock to now - and a list of engine mods that gave me the power.

Stock 1Z TDI is 90HP (66kw) Engine and that is 43.7kw ATW for me.

Your car does sound like it has been chipped and a bit more. A Chipped car boost spikes and you should run a boostvalve of some sort - if it runs in parallel with the N75 you can set it to limit boost spikes. Set it to pop at 17 or 17.5 PSI. You should not be going over 18PSI on that little snail.

**gldgti** · 20-04-2011, 09:06 AM

Heres my new dyno plot to keep good records of my progress...

I also posted it in your thread Marko just to show a side by side comarison of small/big turbo

The only part of the plot that's a little bit awry is just at the top of the rev range on the red line. I would say that the dyno operator took his foot off a little early. There's no reason mechanically speaking with the injector pump for that dip at the end, other than a decrease in accelerator setting. I think I'f I'd assured the operator that is was OK to rev it past 5000 the result would have been even better.

Still, you can see from the plot that theres a decent 10% gain with that 1/4 turn of the fuel screw. Now I just need a decent intake to take the load off the turbo and free up that power.

**Jarred** · 20-04-2011, 10:52 AM

Yea, defiantly. Little bit more fuel defiantly made a difference!

**gldgti** · 03-06-2011, 03:47 PM

Well, bit of an update. Might keep this one going for a week or so.

Car is off the road due to I had a couple of oil/coolant leaks I wanted to take care of... so I got it up on stands to take a look around and found a million things to do.

> new front brake hoses
> turbo wastegate bushing needed attention (was working its way free of the turbine housing)
> 2 minor coolant leaks from ageing and impossible to find hoses
> oil leak from valve cover
> oil leak from oil filter housing
> a/c line damaged from rubbing on intercooler (looks like the intercooler has moved back at the bottom a few mm at some stage... ahh well.)
> still not happy with intake manifold
> minor oil leak from turbo oil supply line fitting.

with all that on the list, i decided to take care of all of it at once so I can actually enjoy the car a bit. so i have ordered:

> stainless bends for new custom coolant hardlines to replace crappy old rubber hoses
> silicone end couplers for ^^^^
> a fancy oil cooler kit (with thermostat) from TPR engineering (thanks Chris!)
> sourced a couple of brake hoses
> can't find an a/c line, seems like my diesel is different from all the petrol models
> found a manifold at Camden GTI that I like and picked it up. Its from a 4 cylinder transporter TDI and looks uncannily the same as a PD150 intake, (don't worry folks, I've even done some work on my custom manifold project - not giving up on it I just want something bolt on at the moment so I can get my custom one done right)
> drew up and ordered a couple of stainless lasercut flanges to bolt up to the t4 manifold to replace the factory EGR/antishudder valve with a straight pipe.

hoping to have it all done for, or during, the long weekend.

should be good!

**gldgti** · 04-06-2011, 07:46 PM

had a visit with the dentist this morning so the going was pretty slow today but I got the turbo refitted and the new manifold... which took a LOT of cleaning. i spent half and hour with the karcher and 2 tins of degreaser

car all apart...

manifold in situ

not a lot, but there is a tiny bit of clearance there!

the stock manifold

**Greg Roles** · 04-06-2011, 08:14 PM

Good stuff mate, cleaning out manifolds has to be one of the trickiest jobs there is.

Also good to see you maxing out the impeller housing space, way to go!