it might be smart to make your valve cover vent go back to the air box. also you should try running a dv instead of a bov. both are releasing metered air, causing issues. she might run better!!!!!!!!
it will only vent metered air if connected to the manifold (like the NA engine)
Quote, originally posted by booested4door » it might be smart to make your valve cover vent
Well fella's, the full exhaust is now on which is a 2.5" full mandrel system with a resonator & high flow rear muffler.
The car is now nice & quiet to drive, idles nice & after a few runs, I'm seeing better increases.
I've since increased the ignition timing & set boost at approx 10-12psi & now it's taking off!
This would eat my old 135hp NA setup for breakfast!
The plug's are mk4 GTI (AGU) plug's. You don't gap them, as they are 3 prong plugs.
I've alway's ran my valve cover breather into catch can's. It prevent's the buildup of crap in the intake system. I see this in new VW's all day everyday!
So far the BOV hasn't given me any trouble with unmetered air, or causing running rough.
At the moment I'm getting closer & closer to the tune. It's just timing & boost. Fuel is spot on!
Quote, originally posted by DaBeeterEater » id try some nkg iridium plugs man they are the shiz lol, bkr8eix,
id be very curious to see what this thing makes on the dyno lol, looks awsome man btw where you located at ?
Might try those plugs later on. At the moment it's all working out pretty good. It's turning the tyres through the first 2 gears, so I'm slowly getting there. More tuning over the weekend.
Just a pain in the arse procedure!. Floor it, diagnose what it may be, stop, adjust boost, timing or fuel & try again. Only touch one thing at a time though, as it's easier to workout what does & doesn't improve.
Right now the timing & boost seem to be getting closer, now I need to richen it up some more. It's starting to lean off in the higher gears under full throttle at high rpm's, due to increased boost & timing.
I'm located over an hour out of Melbourne, Australia
Quote, originally posted by nickzom » i am surprised you got it running good with the stock fuel disto. thats what makes me happy.
i have a Audi manifold, turbo, wastegate, and downpipe, Audi Intercooler, and Audi oilcooler.
so all I need is a WUR then.
The fuel dizzy/airflap assy I've got is off an NA Volvo 2.2L from 1983 I think. The air flow sensor plate is larger & lifts up more than the stock VW one. This is how I ran it with the slightly modded NA 1.8L & it provides better throttle response & better fueling over the stock GTI setup. It also improves bottom end torque as well, but seem's to be upto the task of FI too.
The only mod I've done so far to the fueling system over a stock setup so far is fit an Audi 5000T warm up reg with the vacuum/boost supply to the large fitting above the barbed fitting. Not the barbed fitting!
I'm yet to adjust the system pressure with the shim's.
Modified by Mk1-20V at 12:39 AM 10-2-2009
Modified by Mk1-20V at 12:47 AM 10-2-2009
Quote, originally posted by nickzom » is that compared to the MK1 Airflap? I have a MK2 so I think I will be good
Yeah it comparing to the mk1 airflap. But I think the mk1 & 2's are the same.
I'm using the complete Volvo 2.2L assy. Airflap & fuel dizzy.
Quote, originally posted by nickzom » MK1 is 60mm right? my car has a 80MM flap.
I'll be honest & say I'm not sure. I haven't' seen a stock GTI setup in years.
Some more pics for the sake of it
Innovate Motorsports Air/Fuel meter. Awesome bit of gear & should be on everyone's list for the home tuner!
Happily idling away at 14.5-.14.9:2
Fitted the LC-1 in the rain tray. The oxy. sensor lead isn't long enough to reach into the car
Callaway boost gauge
The matching pair of tuners tool's!
I'm still slowly honing in on the tune, but I'm now running out of fuel up top in the higher gear's/load, so the car is booked in next Fri. to have the aux. injector hosing made.
I took a friend for a spin on the light setting & he reckons it's alittle bit faster than a lightly modded WRX. Not sure on that though. It's scrabbling for traction in the first 2 gears, but it's still slow to me!
Got some more work done this arvo & also getting to the end of the part's list.
The faster I get this done, the sooner I can move onto other projects.
Fitted up my new ATE Powerdisc's & Pagid brake pads front & rear
I also decided to give the underneath a pressure wash, due to the weekend away bush bashing a few weeks ago.
Fronts are Corrado 280mm discs & stock Mk1 GTI style pads.
Rears are just standard size Mk2 16V rear disc's & pads
Well I finally broke something today.
My old ABD short throw shifter. The top relay lever broke clean off the shaft!
Stopped,opened the bonnet & manually selected 2nd gear on the gearbox & drove back to a mates house for some repairs too.
Other than that, its been smooth sailing. the car is performing without fault. Mixture's are good, fuel economy is the same as before if not better.
I've removed the tuning gear out of it, till I get my next upgrade which will be a MSD 6BTM. Boost retard ignition
The aux. injector fuel hose will be going on the Fri & I'll have some wiring to do as well.
I'm not planning anytime soon on dragging it or dynoing it just yet. There is still some little bits & pieces I'd like to do to make it more consistant in power delivery.
At the moment, I'm driving it 200km a day round trip for work & more than happy to drive it, as it's nice & smooth & alittle quieter than before. Although with the 13b style idle & weber throttle body, it's a pain in traffic!
I can now see why VW/Audi used a twin style progressive throttle, as a large single is just too sensitive on take off
I did manage to get in a drag race last night against my brothers mid 13sec 6L V8 family wagon just for interest sake.
On low boost (10psi) & rolling along in 1st we nailed it & it was pretty even steven till about 110km & he started to pull away.
Then we tried the 80km roll on. In 3rd I pulled a car length & stayed in front till 140!
I had no expectation's of how fast it would be or how much power it would make & I was alittle suprised how fast it goes.
I honestly didn't think it would be this fast.
Hopefully soon I can turn it up some & be consistent, once I get a few more upgraded component's incl. a MSD 6BTM
Well not much has been going on apart from driving the car everyday & no problem's have arose since getting it going.
I managed to get in some time to get the Aux. injector fuel hose made & then wire it all up today. I also tested the system to see if it would all work
System all up & running
The cold start valve outlet
With the Hobbs switch bridged out
I'm yet to hook up the A/F meter & see what's going on. I'll do that once the MSD 6BTM has been fitted & then see how it all goes.
Modified by Mk1-20V at 7:54 PM 10-11-2009
I also another xmas present today. I ordered it Mon. night AUST time & it arrived THURS. morning form the States! Hell yeah!
All my Ignition component's arrived today incl. MSD 6BTM & RPM limiter pills, Blaster 2 Coil & bracket, Ignition Leads & separator's.
This weekend should be fun.
Once this is all fitted, I'll refit the boost & A/F meter & hopefully start to turn the wick up on this 300+K old stock GX engine! hahahah
well I finally managed to get some more work done, but it was a very very slow process. I started working on installing my new ignition when a friend decided to come down & help me. Well it was only a matter of time before the booze came out. That basically put an end to my progress.
I got the MSD & coil mounted & ran the wiring & started on the ignition lead's
MSD box mounted up in the rain tray against the fire wall. I also fitted a 6600rpm limiter pill. I think I will change this back to a 6200 or 6400 pill.
MSD Blaster 2 coil mounted under the Expansion tank.
Onto today. Very slow & one very "very" bad hangover!!!!!
I finished off all the wiring, made the ignition lead's & got everything tidied up.
Bit of a mess under here, but aren't all Mk1's like this?
When I built this Mk1 I mounted alot of stuff out of view to clean up the engine bay. The only place to put it all is in the cabin under the dash!
Here is the TCI switch mounted up
Mounted up the Boost retard controller.
With all the lead's made & fitted
With everything refitted, the MSD is hidden away not too bad.
Anyway, I did get to drive it & have a quick play around with it tonight. I've now wound the boost upto 15psi & I can safely say the car is now fun to drive!
There is still some tuning/sorting out to do, as it now is just starting to lean out in the top end. I'll have more of a play around tomorrow. I think I'll start increasing the system pressure, to supply the aux. injectors with some more fuel & also retard the cam timing alittle bit. I can start to feel the engine nose off near the topend. I also had this problem when it was NA with the 270 Autotech fitted. I found 2-4 degrees retarded made a big difference to topend.
But just going off initial setting's, I can roll along at 60kph in 2nd & plant it & it will start to break traction. Whether it is turning the tyres or just trying to yank the steering wheel out of my hands & skipping the tyres, it's now very fun. It also try's & yanks the wheel in 3rd roll on from 80 too.
Well I had alittle bit of a sleep in but managed to pry myself outside to have a play around with some System Pressures on the K-Jet.
Here is what the system pressure was before
Here is where the system pressure regulator is located on the side of the fuel distributor. Above it are is the warm up regulator supply, then the fuel return & then the cold start valve fuel supply.
This is what I'm going to adjust to increase fuel flow onto all the injectors incl. the aux. injectors too.
Here is what the regulator looks like removed. This one is out of a spare fuel dizzy I've got here & what I raided the o-ring & pressure spring shim's out of
Here is the one out of my car :Note the two shims on the left of the o-ring.
Then measure what size the shims are to increase or decrease if need be the fuel pressure.
My stock shims were a 0.30mm & 0.50mm giving a total of 0.80mm.
The fat shim was 1.3mm, so I installed this along with my other shims giving a total of 2.1mm
Everything refitted & onto testing the fuel pressures.
As far as how much improvement is made.
It no longer lean's out in the top end & keeps a stable mixture right through the rev range, although on initial boost build up & can shoot as far as 9.5:1 A/F, but quickly lean's back off to normal.
Mind you today was 26+°C & I didn't have any problem's with pinging etc.
Very happy with all this has turned out.
Only after 3 full days with the boost turned upto 15psi, the clutch is starting to let go.
Alittle pissed, as it's only a new clutch that I fitted when the engine let go & its only done approx 20K & that's all highway use too. Its also a Heavy Duty job with the 16V pressure plate.
So at the moment, I've had to wind back boost pressure to wastegate spring tension. approx 6psi!
I also haven't been riding the clutch either. All the work its done so far has been roll on full throttle stuff. It must be making some good power! haha
I think I'll have to source a button clutch in the mean time till I get the auto done.
I'll also refit the diesel 4spd & probably lock the diff too, so I can drag it.