Turbo Project

[wicca]

Due to some interest I will post here onwards what I know about turbocharging the infamous 16v engine. I will also try to explain and reason why I am doing this conversion, how am I doing it, how much is it going to cost me.... just about everything.....


Read on:

 

[Icecavern]

sounds good. The main problem seems to be getting a manifold IIRC. Unless you havea custom one made.

Pete

 

[wicca]

WHY ?

After a brisk ride in a friends custom turbocharged Astra 16v - of about 250 HP - and making a laugh of a few "pure racing" and 'look how rich i am a have me 645i" drivers - I got very ill.... I got the turbo bug - it strikes you through your eyes looking at the insane acceleration of a 13 year old hatchback and clogs in your brain . forever. Suddenly beer is not tasty anymore , nor is your girlfriend as ineresting as before. And you start asking yourself quiestions - can I do it to my car!?! you quickly go through the 20 century greatest IT invention and read and read and read... and you discover that you can !

HOW?

this is the difficult bit - do you want a streetable every day car or do you want a pure weekend racer? can you afford such a project? well I can't . but that does not stop me as I am going to be reasonable and not cut corners - I will do it once and the proper way. I am not going to go into too much detail apart from the parts I am going to use. When you are dping such a conversion from NA to FI... it is up to you what you will achieve... turbos are tricky as they rule the powerband, so does compression... it is maths basically. choosing a turbo is the trickiest bit, as there are 1000's of options , sizes makes etc. I go for the full monty - Turbonetics T3 Super 60 (external wastegate) - 34lb/hr rated at 340 BHP. It a reasonable choice to achieving 250whp ( as much as my 020 gearbox can take. i hope) with a 5 liter ICooler of a 530d . Why external wastegate? well it does not restrict flow as much as the internally wastegated turbos.

Compression - that was hard choice - as it is going to be a daily driver - i need something that can take traffic and has some power off boost for economy. So the compression is 8.5 with forged pistons.

Manifolds, Injectors, management. - there are a few firms that offer log stile manifolds for turbo projects - I went the other way as I find them restrictive and they require change of the inlet manifold (more money) . So I am going to have a custom built manifold able to take turbo and external wastegate.

Management - after a lot of though - Digi 1 from the G60 VW sista - it is ok up to 1 bar of boost. it is a cheapy thing to do but I am on a budget. Might have the piggyback SMT6 later on if needed as the new version has boost control option.

PRICELIST - here it goes ( so far) you decide cheap or not . please bear in mind I live in Bulgaria ( I was born there too )

Turbo - brand new - thanks e-bay - 500 EUR
IC - junkyard ( tested at 3 bar ) - 75 EUR
Blow off - thanks e-bay - 100 EUR
Wastegate - .... e-bay - 150 EUR
Manifold - 350 EUR - custom - to be made
Pistons - ~450 EUR
Injectors - 100 EUR

so far everything apart from the IC is brand new, I am to rebuild the engine ... AAARGGGGGHHHH the engine it is an ADL 1.8 16v


Whether it would be a dream or a nightmare .....

 

[wicca]

sounds good. The main problem seems to be getting a manifold IIRC. Unless you havea custom one made.

Pete

that is the easy bit - setting up the car ( management wise ) is that hard part. that is why a lot of projects end up bust.


that is why I have opted for a reasonable setup - i need reliability . I mean 0.8 bar of boost and 8.5 comp ratio - on a rebuilt engine. turbo is just about right to support that kind of boost without being peaky or laggy.

 

[wicca]

Update:

Pistons are due to arrive.....
Turbo is due to arrive
Injectors are due to arrive...

Everything is down to FEDEX

project is on hold

A bit about the car - high mileage 1.816v Cordoba with upgraded brakes (280 mm G 60 ones) , Bilstein suspension, 15 ' OZ F1 wheels ( to be sold)

BTW I am looking for 16s off a Cupra 4*100 - any ideas???

 

[andyj]

there's a set of Mk3 Ibiza 16" rims in the For Sale section at the mo!

Andy

 

[andyj]

btw, Turbo plans look interesting, keep us posted with pics etc !!

 

[wicca]

yeah I will keep you updated , of course

so far I am still waiting for the turbo and pistons which are on their way ....

the project would be ready in March

I will try to provide pictures of the build up as much as I can

 

[mrcoyote]

Not wanting to be awkward, but would it be easier to put the 1.8T lump in instead?

 

[wicca]

the 1.8T with 9.5 comp ratio there is not much you can acheve with standard internals ... that turbo is too small ( KO3) - and you have to start all over again - pistons, manifold turbo, intercooler, ..... I find it a waste of money.


I have a friend with a Golf 1.8T with chip at 1.2 bar but power dies at 4 500 rpm....and boost falls to 0.9 bar.. all this is done to prevent detonations - compression ratio is too high to boost properly.

 

[wicca]

some changes and updates

Well

everything is delayed..... I changed my mind on the turbo - due to financial reason s and comlexity- I bought a T3 Super 60 Garrett- INTERNAL wastegate. I spoke to a few gurus overhere and was convinced that the boost I want to run ( up to 1 bar or 15psi) does not really require external wastegate.

Injectors arrived - 380 cc ones - look scary - they have two pretty large holes at the tip about 1mm diameter.

I got a full Digi 1 harnes and ECU yesterday for only 60 pounds - off a Corrado G60 and spent last night with a friend of mine figuring it out - it looks pretty simple and straight forward - I am not exactly a master of the wiring stuff, but that will be sorted no problem

The low compression pistons are on their way down here - would be in in a week or so...

As soon as I gather everything I will post pictures of the kit and on the whole process

I am now really getting worried - as parts arrive, and the whole project is to be started - would it work at all ? what am i expecting to break

I need some help guys - I need a stronger clutch for 020 transnission - do you have any ideas/prices???? that is the only thing I have not ordered/thought off - my current clutch is relatively new and I guess would hold up to 0.3 bar - run in boost for the first few km-s..... but after that I have no option and change it

Thanks for the help in advance

 

[Fl@pper]

what pistons did you get ?

i had a hells own job getting anything oversize even at std compression

 

[Ruddmeister]

the 1.8T with 9.5 comp ratio there is not much you can acheve with standard internals ... that turbo is too small ( KO3) - and you have to start all over again - pistons, manifold turbo, intercooler, ..... I find it a waste of money.

Could you not source a 1.8T with a K03S or K04 turbo, plenty of mapping options and anywhere between 220 and 270bhp approx?

 

[wicca]

well it is a french firm - I will get you the details as a frind of mine ordered them

 

[wicca]

i don't like these turbos - KO3s is small , KO4 is a good turbo but expensive and hard to find - brand new costs a fortune and due to tha variable fins - expensicve to repair

I can easily convert my turbo to t3 t4 afterwards but that woul be a stage 2

as I want reliability - everything is to be done step by step with new parts where possible - i am rebuilding the engine and tranny as well - the rest ( suspension , brakes etc is sorted)

it is my daily driver - and I am really in "love" with my car and don't want to change it for anything - yet .... I want it reliable and torquey

 

[hopkinsgm]

...I need some help guys - I need a stronger clutch for 020 transnission - do you have any ideas/prices???? that is the only thing I have not ordered/thought off - my current clutch is relatively new and I guess would hold up to 0.3 bar - run in boost for the first few km-s..... but after that I have no option and change it ...

I think you may want to think about a stronger box in general - the 020 is not known for it's abilities to handle massive amounts of power...

 

[andyj]

02A and cable change would be the way forward for bigger power/torque

02J on the Mk3 Ibiza is also cable change I think

 

[hopkinsgm]

Not sure of specific differences between 02A and 02J - but seem to recall that one of the differences is method of clutch actuation (cable vs hydraulic). Output flanges may be another difference, but I forget.

If the 020 is to be used, suggest the differential pins are replaced with bolts... It's probably a good idea whichever 02? VAG 'box is used tbh

 

[wicca]

why change it before it breaks???

and gboxes are 30 pounds in the yard

I know 020 is not strong but it is a hit and miss thing - people have put 500 whp through them ....

I cannot afford AND that conversion at the moment.... but if it becomes a major problem - I will convert

Probably will have to take a bit more care driving - no drag racing and stuff

 

[hopkinsgm]

By that argument - why bother changing your clutch if, as you stated in an earlier post, your current clutch is fairly new?