Turboing your 9a valver??

[VEEDUBBED 0]

Right then,after starving my G-charger of oil i decided to re-fit my Garret T3/4 instead and also because i just hate the G-charger's constant whine.

I'm using a manifold off an audi S2 20v 5 cyl motor which i got off Ebay cheap,be carefull though as they are prone to cracking all over.

I like the idea of an ext. wastegate because it's simple to adjust,unlike my old set-up that ran an internal gate that was impossible to adjust(and flutterd like mad loosing boost) without jacking the car up.

The manifold fits perfect ly,the problem is the wastegate that hits the back of the O/E 16v inlet manifold,not by alot but enough to make the mani.unable to bolt to the cyl. head.You could get a shorty manifold made(expensive) or do like me and chop up a spare bottom inlet manifold piece and use it as a spacer.

Exhaust down pipe is a bastid to make because the gearchang rods get in the way if you make a 90 degree bend so you'll have to copy my exhaust which i'll take photos of and post up.

I have'nt worked out a way to feed the wastegate back into the main downpipe yet,not much space.

Remember also that the downpipe if 2.5 inch or more will butt up against the ABS motor so rap the downpipe with exhaust heat rap and seal with silicone spray.

One other thing regards the fitting and dismanteling of the turbo for repair etc,inorder to remove the unit as a whole you'll have to use a spare sissor jack jammed in between the block just above the engine mount and bulkhead,this enables you to remove the unit as a compleat unit otherwise the exhaust mani. studs dont clear the turbo manifold's flange while your bending over breaking your back and struggling to remove the thing you'll see why...it's immpossible to do other wise,especially if using turbos such as Garret T3/4's,kkk 26,7's,T4 etc as the turbo slams against the firewall due to having a bigger compressor compared to a normal Garret T3,T25 etc which may come out with out the need for the jack.

Remember also to use 13mm high grade turbo nuts inplace of the crap VW 12mm versions.

I'll post up as i carry on with the job and let you all know if there are any other hitchs,cheers,Andrew.

[VEEDUBBED 0]

I just rememberd another important thing,if you decide to use a Garret turbo remember that the turbine housing's flang will have to be modded because the Audi manifold has a different shape attachment,basicly you elongate the garret's mounting holes to match the Audi's KKK pattern studs.

If using a KKK turbo it will bolt right up no problem.

A KKK 26 is a good turbo to use if you can get the watercooled version,the oil cooled version is ok but less reliable in the long run.

Also try and obtain a .63 trim exhaust turbine housing thats not cracked,which won't be easy..

You may find a good one off a Ford escort T3/4 cosworth which also has a handy tapping for the ox. sensor.

[wilkes 0]

what did you do to drop

compression ? this sounds interesting ,love to see some pics

[VEEDUBBED 0]

2 ABV metal headgaskets when i had the charger,worked with no problems at all,this time i'm spending coin on forged pistons,ARP or Raceware stud and nuts,i've already got a spare exhaust cam as inlet fitted along with a large Bosch fuel pump fitted and a set of 575cc Bosch injectors.

Maybe standalone management in place of the Digi-1 set-up and def. a wide band lambda sensor.

I'll get some photos tommorow and post them up.

[saysomestuff 0]

I'll get some photos tommorow and post them up.

yes please...

[veedub 0]

Tell us more!!!!

[VEEDUBBED 0]

Right,i managed to get a couple of photos today of the turbo installed with w.gate and some of the exhaust downpipe.

Now i'm waiting for a roll of grafiteexhaust rap,a few new gaskets for the inlets and the chopped inlet spacer that will give clearance to the inlet manifold.As i go along i'll snap a few more photos.

[corrado_16v 0]

I see u sad uve got a spare exhaust cam as inlet fitted ive asket some ppl about this befor and didnt get very far what do u have to do to fit a exhust cam as a inlet ive got a spare one eany advice u got wud be a good help :D

 

nice work on Garret its looking good its going to be nice when it all finshet

[flusted 0]

As i always state, you need a modded chainwheel to do the 2 zorst cams and my mate no longer makes them and niether does stealth so its a no go really.

 

Andrew, does this mean your 16v/g60 pulley set will be available as id be interested in that!

[VEEDUBBED 0]

Flusted,depends what you need because that set-up photoed was made up with spare 8v.tensioners,g60 pulleys,Audi 80 bottom pulley for p.s pump etc.

Tell me what you need and i'll see.

Corrado_16,i'll snap a photo of my exhaust cam that's still installed on that engine,flusteds right though,i had to time and work out werte to weld the timing sprocket on right but following the pictures i found on Vwvortex i did it.

[flusted 0]

Just curious to how you did it,just incase i go this route in the future! I can prob source all the parts as i break dubs at work!

[LowG 0]

Run the wastegate on the atmosphere, if you are only using a 2.5" downpipe you want as little backpressure as possible, plus it sounds mean as hell. Just make sure you route the wg dump tube so the gas dont get blown on the engine bay.

 

I wouldnt use the S2 mani personally, it wouldnt be much more expensive to use a cast 16v turbo manifold or a log style one, that way you can fit a wide range of turbos on it. Also they come with external wg port for a tial/greeddy 38mm universal flange. From personal experience its always better to do it right from go instead of going back spending more but I guess you have your own power level in mind and it might work out for you.

 

Beware of engine movement with the turbo being so close to the firewall, other than that 16v turbo is hot 8)

[VEEDUBBED 0]

Aha!,Lowg has finally posted,i've been meaning to get in contact with you for ages mate!,well i decided to use the Audi manifold because i had a spare audi external 'gate sitting around idle,your right about the manifold though the buggers crack like mad and i think the primary pipes are too small diameter wise,no problem as if i'm not satisfied with it i'll rip it all out and use my other exellent quality 16v.turbo mani i've got spare,only problem is that it's for an internal 'gate and slaps the turbo right over the engine mount...

The 2 and a half inch exhaust is only on the car temp. as i'm waiting for a 3inch cosworth downpipe to arrive,fitting that is going to be a real challenge..

LowG,i'm going to be needing a set of 82.5mm 2.0 9A forged pistons and poss. a ball bearing Garret turbo for this motor,PM me with any info and availability,prices etc.

Great to see your company is growing,cheers,Andrew.

[LowG 0]

Aha!,Lowg has finally posted,i've been meaning to get in contact with you for ages mate!,well i decided to use the Audi manifold because i had a spare audi external 'gate sitting around idle,your right about the manifold though the buggers crack like mad and i think the primary pipes are too small diameter wise,no problem as if i'm not satisfied with it i'll rip it all out and use my other exellent quality 16v.turbo mani i've got spare,only problem is that it's for an internal 'gate and slaps the turbo right over the engine mount...

The 2 and a half inch exhaust is only on the car temp. as i'm waiting for a 3inch cosworth downpipe to arrive,fitting that is going to be a real challenge..

LowG,i'm going to be needing a set of 82.5mm 2.0 9A forged pistons and poss. a ball bearing Garret turbo for this motor,PM me with any info and availability,prices etc.

Great to see your company is growing,cheers,Andrew.

 

What manifold is the other one you are using? You could add a external flange onto it?

If I were you i would make a downpipe from scratch, get some guy there in Roma to weld it up for you, maybe will be easier than having to redo the cossie one?

 

Yea i can hook you up with those parts no problem, the prices are all on the website but I will offer a discount to Corrado Forum members :wink: . I'll shoot you a pm with the details.

 

Thanks for the kinds words.

 

regards

 

Miguel

[VEEDUBBED 0]

Hey Miguel,i tried to go onto your website but for some strange reason it only downloads the initial page with the corrado then nothing??,the other mani. is made by 'Turbocar' up in Bologna,no way you can fit a flange,there's just no room on it or any flat edges to work off.

I'm using the 2.5inch cosworth pipes 'cos i only paid 15euro for them!!,the 3 inch pipe should be here soon which cost a bit more..

[LowG 0]

What browser are you using? I can open it from here via internet explorer, if not let me know I will have a word with my web designer.

 

thanks