[Vwdiesel] [Audi-VW-Diesels] Turbo conversion

[James Hansen]

Start with the injectors you have.  No big difference from a performance 
perspective from what you will see running essentially a detuned td.

As far as pumps go, there is no difference in operation between the TD 
and NA pumps aside from the boost aneroid on the td pump.  What it does, 
is add additional fuel when the engine is under boost, and limit fueling 
when there is no boost.  How much and how fast it comes on is 
adjustable, but only adds fuel up to the amount set by the max fuel 
screw.  For starters, you can try this setup without a TD pump, but the 
differences are when you have a mechanical pump set up to provide the 
right fuel under boost, in off boost conditions (like between shifts) 
you will see a puff of smoke until boost comes on.
A pump that has higher max fuel setting and no aneroid will outperform 
the one with the aneroid, but will smoke when off boost.

Just a note about boost pressures.  The difference between a diesel with 
a turbo to add air to increase the VE (volumetric efficiency), and hence 
efficiency overall, and one that is adding additional fuel to take 
advantage of the extra O2 that is there under boost conditions is huge.
More fuel initially may smoke, but the boost pressure rises very 
quickly, is very driveable, has no discernable lag.  This is not how you 
would set things up if shooting for fuel mileage for instance.  No 
aneroid and no puff of smoke will give you an engine that is only a tad 
better than you have, but will run cooler, and get better mileage.
Bear in mind, mileage is largely controlled by your right foot in a 
diesel anyway, so if you can drive for mileage, you will get it.  If you 
can't, you won't.

Some internal differences...
heh...., yeah well, those internal differences are what makes it a 
turbocharged engine versus a non-turbocharged engine.
There are surprisingly few differences between a triathlete and someone 
with good cardio but carrying twenty extra pounds.
Only one will do triathlons.  that is kind of the difference here.

Do not ever delude yourself that you can always drive it with less 
throttle, or that the ONE time you borrow the car to a friend it will 
not melt a piston going up that long grade in one gear too high unless 
you take steps to prevent that entirely.  It's not a big deal to 
accomplish, but exhaust gas temperature is controlled entirely by the 
maximum allowed fueling, and that is what you have to setup with some skill.

It would be monumentally foolish to lose an engine over not buying a 
fifty buck exhaust temperature gauge.  Install this pre-turbo when you 
install the TD components.  Then you know for sure what you have, you 
know the amount of fueling required to attain performance without 
decreasing longevity.   Once this is installed, you can do some WOT runs 
  and see what it gets to.  If the pump is set to factory spec for an NA 
engine, you will very likely see low temps to start with...  So... to 
attain better performance and mileage, you are most likely going to have 
to increase fueling.  Not to be an ass, but if you don't know which 
screw this is, or how to do this, buy a book about Bosch fuel injection 
systems,  specifically one on VE pumps.  You will never regret this.

  Once the pump is set to give a max EGT of 1000-1100, you should be at 
a point of best state of tune and longevity- (with pump timing at 1.00mm)

Need timing tools, ZDMAK is pretty economical, and he has treated me fairly.
-James



David Cook wrote:
> Hey all-
> 
> I know where I could get a kit of parts off a turbo
> diesel Jetta to install on my Cabby's engine.  
> 
> I know the general concensus is that there are some
> internal differences in the engine, but as long as I
> don't go crazy on the accelerator it should be okay.
> 
> Here is the question:  Do I need a different injector
> pump and injectors, or can I continue to use the ones
> on the motor right now?  I know that the pop pressure
> on the td injectors is a little higher, but how much
> difference does it really make?
> 
> Thanks,
> 
> David
> 
> David Cook
> Red '86 Cabriolet Diesel Powered
> Red '90 g60 Corrado 
> Brown and White '78 Westy Campmobile "Bear"
> and others in various states of disrepair
> Pictures here: community.webshots.com/user/superdave5599
> 
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