Just for you info.
A qiuck translation by google and some swedish words in it but you get the idea anyway.
enjoy.
Project Polo TD's 250% performance increase!
Diesel Club Sweden has decided to make two technology projects this year (2011).
An electronic project where a BMW 335d 2010 shall be maximized to the new power level.
This is done through various modifications, but with a pristine engine.
Car two, as this project is about is a Polo 1.4d 1993 model year.
This car must be set against an original car in various exercises.
The idea on this project has been to maximize the car's performance on so many levels it
goes with every step.
We shall as far as possible make all things which this entails.
The guiding principles of this project is that knowledge comes first.
Engine:
The car is std, an N / A, that is, a "vacuum" diesel-1W designation.
Then this will turbokonverteras etc we change name to 1wTD.
Manifold:
New manifold to be built where the pipe length is made equal in length.
For this to be arrange to be made, a CAD file of the flange to the engine and turbo are created.
These will then be milled out of a NC-controlled milling machine. Output for external wastegate.
This is Alverby Racing.
Pump:
If that is the bosch type will be converted to a unique pump for this car.
Internally, this pump have many items made with trådgnistningsmaskiner etc.
Flue gas limiter must be added to the pump when the old pump is not designed for turbo
applications and therefore, this part.
Goran "Diesel Meken" Lindgren in Aneby.
Spreaders / injectors:
These calibrated. Remains at 130bars opening pressure.
The cylinder head / head:
Porting and processed for optimum flow and heat transfer.
The cylinder head / head porting by Jorgen on High Performance Heads.
Camshaft:
If the opportunity arises, the camshaft ground with new angles that are better suited for
overcharging.
Intake:
Portmatching against the cylinder head, crank welded again, turbotrycksnippel added and
polishing. Jorgen on High Performance Heads
Engine Block:
Renovated up that blasted and new coating applied.
Block redrilled or drilled on the new dimension.
If technology enables an adapter ring of piano wire nerfällning so this will be done
New main bearings, etc.
Bottom Bracket exchanged, and all seals.
Pistons and rings:
These refurbished alt replaced with oversize.
Rods:
They X-rayed and ballpeening for better strength.
Intercooler:
Bmw 525TDS. If this is not enough, we will replace it.
Other:
Water pump replaced and the oil pump checked.
Cylinder head gasket is made of 1.8mm copper with std gasket as a template for details etc. are
available. Oil cooler Volvo Group A 95graders thermostat, 15raders oil cooler from the Saab 9000.
Transmission:
By default, this car is a gearbox of the type 085 with mating 8p.
When this box is a gasoline engine custom box that is the ratio of this box is not suited for
diesel. This leads to high revs and low speed.
We will replace this with a box from a golf mk3 1.6 ABU engine.
This box is called the CHL and has a better return.
We will disassemble and refurbish up the box and reinforce all the gears and shafts.
The most famous problems will be eliminated in this process.
The methodology for this is kulpeening.
The goal of this is to achieve a 30% increase overall durability.
According to the information we have in the current situation so that the box in original condition hold for
165nm.
A 30% strengthening materials, gives approximately 210nm.
This along with other reinforcements and "trick" so the box should come up to about
250Nm.
Clutch:
Std 180mm diameter and are capable of 110Nm
New access is built as per new spec. 200hkr and 280Nm.
This means 200mm dia.
We are now building a machine with these target values.
The block is calculated under the following assumptions:
The castings used have the same quality as the Volkswagen's other engines and
production facilities using the same timeframe.
This means accomplish the following:
We know that 1.6liters engine in the Golf GTD designation SB withstand a maximum cylinder pressure on
about 90-110nm. That is, most construction sites, these numbers 220-240hkr 380/420Nm boost 2 -
3.5bar.
Do we take time to add a 40% safety margin on this to remove the uncertainties as
has concluded that approximately 60Nm per cylinder should be a good limit.
60x4 = 240Nm. We, therefore, builds a machine that shells withstand generating 240Nm of the crankshaft.
The pump is built to deliver fuel, equivalent 170hkr.
When viewing the engine technical spec like this:
1wTD std 1W
170hkr/4500rpm. 48hkr/4500rpm
240nm/3000rpm 85nm/2700rpm
Bore: 75mm 75mm
Stroke: 79.1 79.1
Compression: 20.5:1 22.5:1
Boost pressure: 1.8-2.5 n / a
Turbo: Garret TB2514 465555-2/3 Plugged wastgate. n / a
How much can withstand engine and transmission?
This is where our collective thinking about any problems we will try to
prevent as much as possible in the drivetrain.
Boost pressure:
Boost pressure will be around 2bar.
Past experience has shown that the engine can handle this.
To re-create the margin so kulpeenas candlesticks etc
Surface structure AB in Arboga is project partner in this.
Heat:
What we know is that the heat will be a problem.
We must cut down this factor to its minimum.
Friction, degrees of combustion and maintaining lubricity are all things that affect.
The back pressure creates heat that is known to all activities that can reduce this to be made;
manifold with good flow, cylinder head ported cylinder head, etc ported by Jorgen at High Performance
heads. If we can not bring down the exhaust temperature "so we add a water / ethanol injection.
We have this IOM also gained a partner that can heat treat surfaces with
ceramic coating, friction deal with such molybdenum to take down the friction and create
margin against the lack of oil pressure, etc. Metalock engineer has the skills that enable
this. Metalock has been contracted to all the details where you can achieve a positive result
map this should be treated according to their expertise.
Transmission:
Sprockets, stock and house shall kulpeenas, with the goal of raising the building elsewhere.
Surface structure AB, the experience of this process and given opportunities to do what
they can be on various details.
Overall:
Contorted poses problems.
Low turns and high torque is a ödestiger combination, so the tanks have been following.
The turbo was chosen to deliver the maximum pressure at higher revs than usual in a diesel car.
We have experience on how a turbo from the Golf 1.9TD behave and this charge very
early. BMW turbo Garret 2514 is slightly bigger on the exhaust side so that the boost
moves up in the code by about 800rpm. On såsätt we have created a small margin against the maximum
load. Estimated to load the previous turbo max at 2300rpm, new turbo at
3000rpm. We should probably study the wastegate and external use.
The drive axles on this car is the most serious available to the car as std, these are likely to
keep as they are mkt common in motor sports scene in germany eg Bergcup who is back racing.
Where these axes are used because of its strength, etc, we make the same assumption here, it is.
Chassis and brakes.
At the front, is the same principle as that of "bubbles", that is to say the least weak.
You could describe it like this.
When the brakes to move the wheels Ca 2-3cm back. The entire front suspension geometry changes.
The brakes are solid discs front and drums rear, and also leave them little time.
The car wobble like an old horse trailer type, feel like you should dump / tip.
During the steering is fantastic, the car slides forward.
So what are we doing this?
The chassis in general:
Lowering the car with the help of lowering springs 80mm front and 60mm rear.
Shock absorbers replaced the custom of lowering.
Rear axle:
Wheels rear angles adjusted to-2grader camber for better grip.
Stabilizers Rear needed, so one should be presented also mounts etc for this.
If possible adjustable.
Widening ~ 20mm of rear axle.
Front axle:
Rambenen (body structure) is reinforced with the help of a subframe that connects the right side with
the left side via bolts.
Link arms are changing angles as the geometry changes, a brace with unibolts built to take care of
forces in the longitudinal direction.
Shock towers are connected by rods.
Tunnel Reinforcement included the subframe.
All this is done to succeed in maintaining the geometry.
The brake system:
New master brake cylinder 23mm instead of 20.6
Rear: Disc brakes from the Golf GTI 226mm
Brake calipers Passat 2008 aluminum integral handbrake.
Requires re-submission of the hand brake wire and sleeves to take care of the battle.
Then we want to keep the standard wire.
Front: Disc brakes from OPEL Vectra B 256mm x 20mm ventilated
Ok: Opel Vectra B 1997th
Brake Hoses from HEL
Custom stålomspunnet, one part VW Opel second, adjusted length of both front and rear.
The brake relay valve from the Passat 3b.
The widening of the rear axle and the need for wider tires and larger wheels make the body
must change. Although ET measurement is changed to about 13, std is 38. This provides a 70mm wider track.
Wheel arches the rear of the car cover over the wheel at the top, making it impossible to change
needed.
Body:
To enable this expanded body 30mm per side and wheel arch edges from Golf MK1
welded to the vehicle front and back.
Wheel wells moved up x number, etc. for better spins on deck.
The expansion is made of the same type golf rallye alt BMW's M3 (e30) plus
we add the Golf MK1 wheel arch extensions beyond this.
These are shared and plastic welded to front and rear bumpers to get a factory appearance.
The expansion is made by Martin Rosendorf in Steungsund.
Multiple winners in Vallåkra for its breadth tions and modifications of the Volvo bus bodies.
The interior:
Chairs and rear seats from PoloG40.
Glove compartment lock my console from G40
The interior sewn on with a technical nature.
The following thoughts were and were developed.
No hot and cold.
Good support in hand, but also back.
Without slipping into the chair.
Creating a good and durable surface with a respectable appearance.
Michael Thors saddlery in Trollhättan account for this.
Other sponsors and partners, etc.
Autodelar.net All material in standard form.
J.-spec.se All material in the form of gauges, brake hoses, etc.
LG-dismantling all materials needed for the development beg.
Trailer 3500 All transportation sells trailers to many different needs.
Auto Tech Ltd Funded by the coupling.
Elmo Leather Leather / leather interior for details
Plus a lot more people with specialist knowledge who is acting as a sounding board.
ny questions.
Sincerely
Thomas Knutson
Project Manager / Owner
Chairman of the Diesel Club Sweden.
0736-561196
