No. 1 or No. 2. A Diesel Story

[sprstu]

I have PP520 now and have just purchased a South Bend Stage 2 with a G60 flywheel. In some sort of Magic Dream World I would upgrade to the dual side mount TT inter coolers, I know a single FMIC would be cheaper but I really like the idea of staying OEM for some reason.

I dont know that I want to go to Race nozzles, depends on the tune I guess. The PP520 have been in 2 cars and have about 30K miles on them, they are a really good nozzle that are limited with my stock tune currently.

[isonic]

So an update on what I have done to the car:
To finish the piping I needed to get more air into the turbo. I decided to run 2.5" pipe from the air box to the inlet of the turbo. The accordian pipe from the air box is 2.75" ID. To make the accordian fit to the 2.5" turbo inlet pipe I cut a piece of silicone from a hose I wasn't using and sandwiched it between the accordian pipe and the outside of the TIP. Fortunatly this part of the piping is under vacum and not pressure

Jon broke out his welder one more time for me and welded a bung onto the pipe so I could retain the stock crank case vent. Lastly he welded a tab on for me to secure the TIP to the intake using the stock bolt hole.

Final product:

Looking at the turbo. Two 90 degree elbows connected the two segments of straight 2.5" pipe to get from the air box down to the turbo inlet. The 90 elbow on the turbo is a 2.5" by 2.25" reducing elbow.


All to get rid of this restriction:

The right side used to go on the turbo and the inlet pipe connected to the left. You can see how much restriction the old inlet pipe had.

[isonic]

After about a year of driving with the bigger turbo I decided I should get some gauges in the car. Most TDI'ers go with the column mount. I wanted three gauges and I wasn't totally sold on the look of the column mount or any pillar mounts. I went with the simple din mount from 42dd. After doing the install I am not totally sold on the fitment but it is what it is.


I choose boost, Exhaust Gas Temp (EGT) and oil Pressure.
For the boost, Jon welded on a tap to the upper intercooler pipe between the SMIC and the intake:

For the EGT probe I bought a probe from mycruiseagent.com As far as I know he is the only one who makes a long enough probe to put into the unused EGR port on the exhaust manifold and get accurate readings. Just drill and tap a hole into the existing block off plate and insert the probe:

Under normal driving the EGT's run about 650 degrees. Towing my atv they stay around 1050 at 70mph. Towing the atv and four people in the car I was easily able to get up to 1400 before I stopped accelerating.

For the engine oil pressure I bought a kit from 42dd. It connects to the stock oil pressure port on the side of the oil filter housing. The stock sensor is removed and relocated as part of the kit. pretty simple:


When cold and under load I have seen it above 80psi multiple times. At idle and warm it sits about 20psi.

[sprstu]

My mk1 IDI wil read about 80psi until its warmed up, then it idles around 30 and peaks about 60 under load.

Stuff looks good, Paul.

[isonic]

So today Jon and went and logged Intake air temps (IAT). For comparison we logged last year as well before any piping mods were done. So today with it being about 38 degrees C outside we recorded a max IAT of 65C. Last year we ran in 32C ambient and recorded max IAT of 90C. So it looks like the larger side mount and piping is helping out. A FMIC would be better obviously but considering how much less work the SMIC was, I think it is ok.

[isonic]

As much as I like to think I am done with this car. Time seems to prove otherwise. I have a timing belt coming up soon. I came across some deals on a few parts that I may-as well add to the car "as long as I am in there"

Here is a pic of one of the parts I'll be upgrading. This has nothing to do with the TB job, but will be interesting to see what happens with them in there. The nozzle on the left used to be the largest available on the market. The one on the right is now the largest available (the holes are visible to the bare eye). Guess which one I am going with...


And I got another one of these for a new tune, RC4 will not be adequate anymore.


I have a 2000 mile road trip coming up next week so parts will not hit the car for two weeks, but they are starting to arrive.

[JFettig]

we need a fall dyno day!

[SLK]

we need a fall dyno day!

I am down. I am interested to see what my Caddy makes right now with the few mods it has on the 1.6TD.

[sprstu]

I am down. I am interested to see what my Caddy makes right now with the few mods it has on the 1.6TD.

im betting not much more than 70hp

[SLK]

im betting not much more than 70hp

Oh neither am I, I just want a baseline. I am not planning on putting anything else into the motor yet but I might further down the road.

[JFettig]

I can't wait until those new nozzles are set up. Pauls nozzles are definitely being pushed to the max with no smoke at 26psi. Lots of headroom for fuel. We just did his base Stage 5 Custom tune, its gonna be fun!

[isonic]

So Jon and I tuned my car last Thursday before I left for Colorado. Only real difference so far between RC4 and Malone is the pedal map. RC4 brought it on way faster but then the "power" (seat feel) seemed to die on the top end. With the Malone tune the pedal needs to go down a lot farther but when it kicks in it seems to pull longer and through the full range of RPM.

[BimmerTim]

Nice. I really want to get going on some diesel action. The two of you and your builds just push me a little harder.

[JFettig]

Ya know Tim. I have a MK4 Jetta TDI with a bad motor and a motor sitting in my garage waiting for some love....

[sprstu]

I have a bigger turbo, stage 2 clutch, 1.8T PP and a tune waiting for me to get off my ass.