The mk3 1.9L TD power-quest

[gldgti]

i cant wait to see how your car turns out (if you ever stop modding it ) would i be able to leech a quick ride in it next time im in gosford? id be happy to take you for a spin in my gt

anytime mate.. i'm in hornsby every working day too!

[gldgti]

mmmmm power!

the saga continues -

saturday was spent with my good mate and work colleague Mark, as we put a full day into the construction of the mk3's fully replaced exhaust system.

total and complete 2.5" mandrel bent fabbed system from the turbo to the tailpipe - and what a difference its made!

we spent the morning making the downpipe, and the afternoon doing the rest.

the results are amazing, and i'm quite surprised at how well its all turned out - i now have the best of both worlds! the car is actually quieter while cruising, i think because of the lower exhaust pressure in the system- despite being one muffler short now. and when you get on the boost and theres more fuel, a pleasing growl erupts from the bowls of the engine and a rush of torque to boot! i actually achieved some clutch slip in 3rd gear today because of the extra torque...

acceleration everywhere is improved, but the best is the increased revability of the engine, now happy to rev past 4000 whereas before it didnt sound happy at all, now its willing!

and a comment from a work neighbor upon hearing me drive up the road during the first test - "it doesn't bloody sound like a diesel!"

some pics for good measure.... fabbing the downpipe - we made a jig to get it just right and re-used the brackets to ensure its all solid and not putting any pressure on the turbo



making sure it fits nicely....



the finished downpipe - aint it pretty?



the old downpipe and new side by side



Tacking up some of the rest....


big thanks to mark for helping me make the diesel even better!

[Jarred]

cool fun. nice bit of custom work there.

If i ever find one of these for sale....

[gregozedobe]

the finished downpipe - aint it pretty?

i actually achieved some clutch slip in 3rd gear today because of the extra torque...

It sure do look purty ............ (and more efficient too)

I note that you are starting to edge into the area of "consequential" mods (needed because of all the extra power). So are any (or all) of the following now on your wish list ?

Stronger clutch
Better tyres
EGT (pyrometer)
More engine cooling
More efficient intercooler
Improved brakes
Better suspension
LSD (..... and so the list goes on )


As far as diesel engines not having a significantly narrower power band than petrols, you still have a long way to go to convince me, plus I do like to stir a bit too .

Rather than choosing specific "no low rev torque" petrol engines for comparisons with highly modded diesels, how about looking at unmodified engines within the VAG family to see a shining example of what I'm talking about - the latest 1.8 TFSI petrol engine that is going in current Octavias and Audis. Maximum torque from 1,500 - 4,200 rpm, and good power continues through to 6,500 rpm from a stock standard motor (more available with mods, and reflashes are already on the market). And it even gets good economy (not as good as a diesel though). When they release the 2.0 version of this motor it should be a bottler. The 1.9 TDI motor just doesn't compare, and both versions of the 2.0 TDI still have a much narrower torque/power band.

I agree that you do nearly all "normal" driving on torque rather than power, but don't forget that the higher gearing that usually comes with diesels does somewhat reduce the torque advantage of diesels. It is also more important to be in the correct gear to accelarate in a diesel (although the off boost, low-rev feeling of nothing, nothing, nothing, something, WHACK ! can be amusing as long as you don't need to go instantly).

Have fun with your mini-monster, sounds like it will keep you amused for some time to come

[gldgti]

gregozedobe,

you are right ofcourse about the 1.8T engine, and a lot of other VAG engines... but thats not really the point i was trying to make.. i was really trying to demonstrate that theres no reason you can't have a very driveable car with a "narrow" power band.

as to other modifications, i've already put VR6 brakes in it, and i'm not totally happy with the intercooler set up either.

and EGT guage is needed but i wont be doing that until i have a good reason to pull of the exhaust manifold.

i dont think i need a bigger clutch, theres a good chance mine is original and the car's at 160,000km but its not slippy normally, so its probably just getting close to worn. i would say that a new clutch will fix that problem (which hasnt yet reoccurred... yet) and i have one in a box downstairs.

the car already runs on 205/45 16's and i dont think that it needs any more tyre than that - just some better quality ones for my next set.

i will probably change out the current k14 for a newer and larger K04 in time, which i feel will be better matched to this engine going on the turbine efficiency maps i've looked at and the way the boost drops off at higher revs with the k14 now.

[gregozedobe]

The more I hear about it the better your project car sounds

[smithy010]

That's a dead sexy downpipe!

Do you guys have a mandrel bender up there, did you get them done custom, or did you buy the bends and weld them in?

[Jaymz]

Thats fantastic, great write up. In its current state of tune it would have to fly i'm sure.
What does the mk3 weigh? The low weight will help the smaller 1.9 no end, as i would say you would now have the same performance but better economy than my tuned GT. Oh yeh, and for alot less money.
Looks the business too!

Keep up the good work and let us know when you get it on the dyno.

[Greg Roles]

Me likes the way you think. Very nice fabrication, and no doubt the sort of thing a few of us DPF types would like to bolt in. Good to see you keeping the oiler modding bug alive well and truely!!

And Geez Gregoz, haven't you ever heard of the great Aussie concept of wacking a huge engine in an otherwise stock car, without any other mods? Brakes, tyres, suspension...BAH...stuff for wussies. Being FAR too sensible!

[gregozedobe]

And Geez Gregoz, haven't you ever heard of the great Aussie concept of wacking a huge engine in an otherwise stock car, without any other mods? Brakes, tyres, suspension...BAH...stuff for wussies. Being FAR too sensible!

Yeah, guilty as charged I like to see people enjoy the fruits of their labour for a while, rather than wrapped around a tree or on the side of the road with a blown motor. I believe it is possible to mod your car and have fun, and remain alive and legal as well - it just takes a bit more effort is all

Even when I was a young fellah (and I admit that was some decades ago ), I was never a great risk-taker. I was the one who would ride my Yamaha 1100 around the corners at 8/10ths, and then catch up on the straights with a good dollop of power. Several crashes on dirt bikes reminded me about what happened when your adrenaline and ambition exceeded your skill and ability

I know about BIG motors in normal cars without mods - probably the best I knew was a 1969 Monaro that came with a 186ci motor that the owner jammed a big block chevy 428ci into (without changing anything much at all, and trust me, a 1969 Holden 6 cylinder wasn't a good platform to start from !).

He couldn't use full throttle at anything less than about 100Kmhr, as the tyres just went up in smoke It didn't half accelarate after that though, but was very scary in anything less than a straight line, and it took forever to stop At the time we had yearly rego inspections, so he just swapped the original motor back in every year for the inspection (he could do it in an arvo - lots of practice). He didn't worry about being pulled over, RWC's etc, as it was the late 70's and he was a cop. I think they called it "extending a professional courtesy" in those days. I valued my life even back then, so didn't ride with him very much at all.

[gldgti]

Thats fantastic, great write up. In its current state of tune it would have to fly i'm sure.
What does the mk3 weigh? The low weight will help the smaller 1.9 no end, as i would say you would now have the same performance but better economy than my tuned GT. Oh yeh, and for alot less money.
Looks the business too!

Keep up the good work and let us know when you get it on the dyno.

i doubt it would keep up with your GT, and am sure i wouldnt get better economy... though i dont know what i'm getting now after the new additions...

before i was getting 6.5l/100km on biodiesel 100% and about 5.9l/100km on normal diesel. we shall see what improvements there are in time.

i'm not sure what the mk3 weighs, thats a good question. i think it would be less than a tonne, but as to how much less i dont know.

the point of it all is however that its a cheap car - if i get to GT speed then i'll be happy, but this car cost me 7 grand outright and it still has 2 airbags, power windows, remote central locking and good a/c. it still gets nearly as good fuel economy and even with all the stuff i've done to the car, i wouldn't have spent an extra 2 grand yet.... plus its a little lighter, and thus i expect it outhandles the younger models a little.... so for me its the ideal daily driver...

YUP - not project car - DAILY DRIVER - hahahahhahaaa i love VW's.

[Jaymz]

i doubt it would keep up with your GT, and am sure i wouldnt get better economy... though i dont know what i'm getting now after the new additions...

before i was getting 6.5l/100km on biodiesel 100% and about 5.9l/100km on normal diesel. we shall see what improvements there are in time.

i'm not sure what the mk3 weighs, thats a good question. i think it would be less than a tonne, but as to how much less i dont know.

the point of it all is however that its a cheap car - if i get to GT speed then i'll be happy, but this car cost me 7 grand outright and it still has 2 airbags, power windows, remote central locking and good a/c. it still gets nearly as good fuel economy and even with all the stuff i've done to the car, i wouldn't have spent an extra 2 grand yet.... plus its a little lighter, and thus i expect it outhandles the younger models a little.... so for me its the ideal daily driver...

YUP - not project car - DAILY DRIVER - hahahahhahaaa i love VW's.

Yep mine too! Have had many a performance car but the best thing i like about my dub is that its got performance and economy

I think you would be surprised about the performance, we should get a G-Tech and compare. If your under the tonne mine is 1.4t. Our power to weights would be dam close.
My economy is averaging 6.6L/100 we when driving like miss daisy and when pushed i can easily get 10L/100!
I gave a good friend of mine a drive, he's the M car specialist at BMW and he thought it would be good for a 0-100 somewhere in the 6's. Surely yours wouldn't be far off that when tuned with the new exhaust.

[Mischa]

i'm not sure what the mk3 weighs, thats a good question. i think it would be less than a tonne, but as to how much less i dont know.

surely not under a tonne? my mk2 just scrapes under the 1t mark.

nevertheless sounds like its turning into a weapon

[Jaymz]

Coutesy of Wikipedia

The third-generation Golf was elected European Car of the Year in 1992. For the first time, a station wagon derivative was produced, bringing it into line with key competitors like the Ford Escort and Vauxhall/Opel Astra which had long been available as estates. The GTI variants (especially with the straight-four 4 cylinder engine) are considered to be the poorest of the performance Golfs, with significantly increased weight, but with minimal power increases. A "best of breed" VR6 variant exists which was available in a well regarded "Highline" trim; this 2.8 L VR6 engine gave a significant boost in power to 174 PS (128 kW/172 hp) for the Mk3, a car weighing only about 1285 kg (2836 lb). Compare that to the Mk2 GTI that weighed 285 kg (629 lb) less but had only 139 PS (102 kW/137 hp) and a much smaller engine to tune (1.8 L). A convertible version of the Golf Mark 3 was launched as the Cabrio (Typ 1E). The VR6 offered a top speed of 138 mph (222 km/h) - almost unbeatable on any hatchback of this size available in the early 1990s, outperforming even the Ford Escort RS2000, Rover 220 GTi and Vauxhall Astra GSi.

A 16-valve version of the third-generation Golf GTI was introduced in 1993. This model was greeted with a muted sense of disenchantment by the motoring press[citation needed]. The engine was enlarged to 2.0 L, with power now reaching 150 PS (110 kW/148 hp). While underpowered compared to the VR6, it was still relatively popular with driving enthusiasts in Europe (North America didn't get the proper GTI version, but had the name applied to the VR6 engine). Once again the Golf Driver version took its place as the official GTI-look-alike but with a more humble single-point injected 1.8 L engine.

The Golf Mk3 was also the predecessor of the "diesel craze" that swept through Europe in the late 1990s and early 2000s, when Volkswagen introduced the direct-injection system with the 90 PS Golf TDI in 1993. The 1996 TDI, at 110 PS (81 kW/108 hp) for a 1.9 L engine, wasn't the first diesel engine installed in a road car to achieve over 50 hp (37 kW)/L, but it showed the public that diesel engines could be powered without losing their fuel efficiency, while also retaining massive amounts of low-end torque, in the TDI's case, 235 N·m (173 lbf·ft) at 1900 rpm.


1998 Volkswagen Cabrio GLSAlso offered was a naturally aspirated (i.e., not turbocharged) version of the 1.9L diesel engine, the SDI, offering 47 kW (64 PS/63 hp). This variant is considered to be particularly durable.

During the 1990s, Volkswagen sponsored three high-profile rock bands' European tours, and issued a special-edition Golf, with distinctive exterior markings, for each: the Golf Pink Floyd Edition (1994), the Golf Rolling Stones Edition (1995), and the Golf Bon Jovi Edition (1996).

In 1996, Volkswagen produced a limited quantity of 1000 special-edition 3,5 door GTI Anniversary model, celebrating 20 years of the GTI model. This had the usual GTI specification but came equipped with special chequered Recaro front sport seats and matching rear seats bearing the GTI logo, red seat belts front and rear, half-chromed and leather golf ball gear knob, red stitched leather steering wheel and handbrake gaiter. The release knob on the hand brake was also red and silver instrument dials. Floor mats also had red pipping along their edges. The red theme continued externally with a red striping on the bumpers and red brake calipers. The wheels were 16" x 7.5" split rim BBS RX II alloys, visually similar to the 15" that were found on VR6 model. Brush stainless steel rear twin tailpipes on the exhaust and smoked front fog and indicator lamps to match the rear lamps. 3 optional extras were made available; electric sunroof, air conditioning and metallic black paintwork. Insurance was based on the standard GTI which made this version a very desirable model. The edition was sold in only 6 colour schemes and the 1000 number figures that were produced was as follows; 600 8 valve models, 150 16 valve models and 250 TDI models. The diesel model was only produced for the European market and wasn't sold in the UK. Unfortunately many of the models fell into the UK company car and lease market prior to the second-hand market and its believed only a few hundred still survive.


I want a Rolling Stones version!!!

[GoLfMan]

i doubt it would keep up with your GT, and am sure i wouldnt get better economy... though i dont know what i'm getting now after the new additions...

before i was getting 6.5l/100km on biodiesel 100% and about 5.9l/100km on normal diesel. we shall see what improvements there are in time.

i'm not sure what the mk3 weighs, thats a good question. i think it would be less than a tonne, but as to how much less i dont know.

the point of it all is however that its a cheap car - if i get to GT speed then i'll be happy, but this car cost me 7 grand outright and it still has 2 airbags, power windows, remote central locking and good a/c. it still gets nearly as good fuel economy and even with all the stuff i've done to the car, i wouldn't have spent an extra 2 grand yet.... plus its a little lighter, and thus i expect it outhandles the younger models a little.... so for me its the ideal daily driver...

YUP - not project car - DAILY DRIVER - hahahahhahaaa i love VW's.

are you coming to Nats mate? i want to pick your brains over a few beers about Bio Diesel and diesel tuning in general