Ibiza 6k1 TDI + GT2052v

[Blaze.BG]

Well for my b-day i'lll buy New intercooler Greedy , and the flange for the turbo is ready. In a few days i'm gonna start assembling everything. Here in my town we still have snow, but i can't wait...

I have a lot to write here...in past week i was working on polishing the wheels, buying intercooler, finding 12mm fuel pump piston, and i got it and now i'm looking for brakes update to buy. May be from S2.. it is easyest and almost the best brake update for 6k

 

[Blaze.BG]

Hello hello again!
I have to tell you that fitting the GT2052v on old exhaust manifold was an adventure. The making of flange was easy job, but to fit the turbo whre it must be was a hard work. We have mani broblems with the oil feed pipes, but in a few days they will be removed

First of all, the turbo was mounted with "up standing" - that is how we call it, when the turbo is over manifold, not under it how was the old one.

manifold:

turbo:

flange: (NOT the perfect fitting model)

after few improvements:

manifold with the flange: (perfect fit model)

I disassemble the turbo and rotate whole geometry to fit oil feed holes vertical and in propper position.

Together:

Now we are mounting the intercooler and turbo pipes for it. I'm looking for a nozzles 240um for now, and when i make the change in fuel pump with 12mm piston, i think to get ot 260um nozzles or may be more

With all these changes i must find and a MAP sensor for pressure may be to 3bar. And i'm thinking now for gauges like boost meter, oil temp, and oil pressure. somewhere between all theese i must buy a oil cooler! Better cooled oil for turbo is a good piont!!!

And in my free time i'm working on this:

 

[Seatmann]

Maybe some race nozzles?

http://drivbiwire.auto.officelive.com/nozzleselect.aspx


and perhaps a 4 bar map sensor?

http://www.darksidedevelopments.co....map-manifold-pressure-sensor-03k-906-051.html


I like the way you've got the turbo to fit in there, I see a lot of guys on the tdiclub having to modify the engine mount to get a decent turbo in.
I also think it might be worth looking at getting the nozzles you need for the 12mm pump and just having them set up for the other pump for now, then get them re calibrated later for the extra flow needed.

Ps the centres are missing from your wheels

 

[Blaze.BG]

Maybe some race nozzles?

http://drivbiwire.auto.officelive.com/nozzleselect.aspx


and perhaps a 4 bar map sensor?

http://www.darksidedevelopments.co....map-manifold-pressure-sensor-03k-906-051.html


I like the way you've got the turbo to fit in there, I see a lot of guys on the tdiclub having to modify the engine mount to get a decent turbo in.
I also think it might be worth looking at getting the nozzles you need for the 12mm pump and just having them set up for the other pump for now, then get them re calibrated later for the extra flow needed.

Ps the centres are missing from your wheels

hahahh I will calibrate (remap) ECU when i have all parts together...nozzles and pump element missing for now. Until then i think the car will be able to "move" so the maping will be in the end

The centres of my wheels ?!?!? Oh my god i was wondering what's wrong here

And.... happy again .... my clutch upgrade is comming soon.
Here in Bulgaria is very popular to replace the original flywheel (damper one -google translated) , with a G60/VR6/ABF set.

What do you think about this??

 

[Seatmann]

Absolutely, that's a common one on a lot of the tdi's, the only hassle is if you have a 6spd box the G60 doesn't work and the kit is way more expensive. Not a problem for me as I prefer the 5spd box anyway

That same guy

http://www.darksidedevelopments.co.uk/transmission/

does the VR6/G60 setup as well as the southbend ones too. Some folk have found them cheaper but anytime I've looked nobody else has them in stock lol.


Glad I pointed out the wheels before you tried fitting them:thanks:

 

[Blaze.BG]

Hi again maniacs
I've started work as a manager of a holiday property, on our Black sea coast (Sunny Beach) and have a lot of work.

But befor i get to black sea coast:

- new MAP 3bar - BOSCH: 0 281 002 177
VAG: 038 906 051
- new vacum pipes
- turbo pipes assembled and the cooler
- we make custom oil feed pipes in one factory. It's great.
- changed filters and oil 5w40 Total Quarts 9000
- front top crossbar
- exhaust system was updated with "GT exhausts"
- - - Retro auto party
This is a bulgarian girls and one old beautiful car made in Bulgaria and Russia.

Back ot the work. The mounting and installnig ot the new MAP :
(AFN until 98' are with integrated MAP in ECU)

I decide to put new MAP here:

First locate and get out the ECU.

After that you will see the MAP inside. Cut it out

Here is the wiring for MAP:
(It's your choise, will you use the original air temp sensor or this one in the new MAP)

And that's how looks the new wiring:

Almost i forgot:
The EGR finaly fully removed and fixed:
(Home self made)

That's all for now For more information .... come to Black sea coast

 

[mrannikk0]

Whoa!! Thumb's up for this project!! Have You tested engine performance at dyno run??

 

[Blaze.BG]

Not yet
Waiting for the nozzles and upgrade of fuel pump, then i'll go on dyno. here is very expensive so i decided to skip it for now. (Somewhere around 130hp i think)

Again i'm in Sunny Beach and working! In October will have more more more info and pics
I decided to make tha car white, and the rims are in GWorkshop for 3D painting.

Nice but verrrrrrry slow

 

[Blaze.BG]

Hi hi HI again

After hard work season again i''m with my TDi in the garage.

News for the setup will be posted soon. For now, i''m just gonna say...
+ mounted front intercooler
+ mounted turbo and oil feeds
+ 250um nozzles
+ flywheel and clutch from ABF (now)
+ almost finishedfully repaired rims

Pics and more info soon... but i have a question:
11mm or 12mm fuel pump piston should i get for those 250um nozzles???

 

[Seatmann]

I suspect the 11mm would be big enough but there's no harm in having extra room to play with. My 10mm pump is managing fine with 232 nozzles so far. I haven't had to push it that hard yet though so not 100% sure how it would cope with more demand.

Is that the HFLOW-X nozzles you're using?

How much power are you aiming for?

Maybe more than the sachs VR6 kit can handle?

 

[Blaze.BG]

i''m thinking to start and make some adjuxtments with original 10mm , and may be later 11mm, or 12mm with 280um nozzles but this is in the far future....

Some people told me that the 12mm +250 nozzles will be bad for timing belt!!!

The nozzles are Bosio race . And i''m aiming for 170-180hp with this setup, and may be some day 200+

 

[Seatmann]

You'll get that easy with the 10mm pump and those holes, race 520's I presume?

Don't know why 12mm and those nozzles would be bad for the belt either, not come across that before.

 

[mrannikk0]

Some people told me that the 12mm +250 nozzles will be bad for timing belt!!! )

Don´t worry!! It´s just rumor! In my Cordy work just fine!

 

[Blaze.BG]

So SEATMANN says that even with 10 or 11mm piston, everytning is fine!

And MRANNIKK0's opinion is thaht even with 12mm and 250um will be better.

I''m wondering why 10 people have 15 points of view (including friends in BG) ?!??!
With 12mm i could have some problems with timing belt, because i'll have more fuel that i can use....
With 10mm few guys told me that well be OK!

I'm wondering where goes 11mm piston?
May be it will be perfect, but 11mm and 12mm are on same price so is a difficult decision for me.

 

[Seatmann]

I spend a lot of time on the tdi club, maybe to much lol and come across a lot of tuning stuff. They didn't get all the tdi's we did so they tend to squeeze as much as possible out of anything they have.

The 10mm pump will manage 180 without a problem anyway, maybe need to go to the 11mm for more but unless you're going nuts I think the 12mm is maybe overkill. The 11mm is easier to get because it was standard in the automatic, don't know if anything used the 12mm.

I don't see how you'd have any issues with the timing belt with the 12mm though, or are you talking about the timing? As in the pump timing?

 

[Blaze.BG]

I don't see how you'd have any issues with the timing belt with the 12mm though, or are you talking about the timing? As in the pump timing?

Thanks for that!!!!
For sure i''ll start with 10mm and we will se how it will be...

About the 12mm and timing belt, some guys told me that it will be hard for belt, because pump will get more fuel and pressure in less time- so..... engine will make more rpm, and this will be difficult between pump and belt....(with tose nozzles i will have over fuel, which i can''t use...) Hope U understand me

 

[Seatmann]

Yep, more fuel being pumped adding more pressure making it harder work for the belt. I'll look into that, never heard it before.

 

[mrannikk0]

And MRANNIKK0's opinion is thaht even with 12mm and 250um will be better.

No sorry! I didn't mean that! I just tried to say that engine durability don´t suffer that much.

About the 12mm and timing belt, some guys told me that it will be hard for belt, because pump will get more fuel and pressure in less time- so..... engine will make more rpm, and this will be difficult between pump and belt.

In longer use this could be a slight problem. I have never heard it too! I would say that pump itself don't give higher rpm. It just runs them faster! After nozzles, pump and better camshaft You can take rpm little higher.

This is taken in my RR! With this setup it´s possible to take 6300rpm at least.

Now I need to get on dyno and get some readings out.
Then remap ECU! New camshaft did add some more RPM but after remapping is possible to take much more! Quite high readings to diesel!

 

[Blaze.BG]

Aham Thanks mrannikk0 ! Then after i finish with everything else, start and test engine if all is OK, i''ll get 12mm and prepare for remap.

For now with this setup i and few friends will remap a little bit (one of them whole life is making his diesel cars better, but only FORD )

 

[Blaze.BG]

Still don''t have bigger pump, but tha car is tested, and i''m glad to say everything is OK!

I''m surprised how easy and nice engine is working! No smoke, no problems. For now everyting is fine!
Just waiting the bigger pump piston, and we go for remap

One problem is pouping up by.... I need to isolate heat from the turbo. Intake is getting verry hot there
Do you have some reccomendations ?