Toroke

Okay. I need help. I originally did the noob thing and made a thread saying something like "I'm stupid help," but after, quite literally, hours and hours of research... I believe I'm educated enough for this.

The project: Turbo the D16, ending up with 175-200 horsepower running sub-14. It's gotta be able to kick the *** of my buddy's 2003 Jetta Wolfsburg Edition (180HP 1.8T). The catch is, however, reliability. I need to have this car as reliable as humanly possible, since it's gotta last me one more year in high school and all four years of college. So, to sum it up, D16Y7 turbo'd, where reliability is crucial.

So far I'm looking at a log manifold (BMCrace.com), T3 turbo (not sure what size, but probably Garrett. I'd appreciate if someone could elighten me on the sizes), Greddy BOV, whatever intercooler, not sure what wastegate, and then somewhere I've got to get intercooler piping and a downpipe to fit my setup. I then need to relocate my catalytic converter (since it's originally welded to the exhaust manifold, RIGHT where the turbo/manifold/wastegate go), as well as attach a 2.5" cat-back. After that, it's just gauges I believe (getting oil temp, oil press, boost, air/fuel, and volt). Eventually, I'm going to try saving up the money to get pistons and rods (do I need anything else?) to strengthen the engine for the boost. Now, I don't plan on getting on it too often, but I need to have my fun.

Now, is this possible to achieve 175-200HP sub-14 on stock internals RELIABLY? I'd like to do this as cheap as possible, maybe 2000. 3000 at absolute most. Also, could someone enlighten me as to what I should do for fuel management? Fuel management is definitely my weak spot. I know I'll need injectors (probably 450cc DSM), maybe a Walbro 255 fuel pump. Other than that, I don't know about it. If anyone's got any questions, comments, concerns, or advice from the same/similar project, please help out. I'm really interested in doing this, and I've learned a TON so far. I also need to find a good tuner around northeast Ohio if anyone knows one.

Thanks, everyone. I appreciate it. And in your responses, please use minimal abbreviations. Or at least explain them first if they're not really common. As stated, I'm learning.

MikeD718

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Toroke &raquo;</TD></TR><TR><TD CLASS="quote">
Also, could someone enlighten me as to what I should do for fuel management? Fuel management is definitely my weak spot.</TD></TR></TABLE>

Uberdata look it up.

Toroke

Well I don't know much about that, other than that it basically allows you access everything in your ECU (handy with a laptop). What all would I need with it? Just injectors?

specv5150

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by MikeD718 &raquo;</TD></TR><TR><TD CLASS="quote">

Uberdata look it up.

</TD></TR></TABLE>



<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Toroke &raquo;</TD></TR><TR><TD CLASS="quote">Well I don't know much about that, other than that it basically allows you access everything in your ECU (handy with a laptop). What all would I need with it? Just injectors?</TD></TR></TABLE>

PC capable of running software (preferably a laptop)
burner to burn chips
cable to hook burner up to laptop
chips
working knowledge of what you are doing or paying someone to do it.

Anyway reliability is all in the tune and parts used. If you use a cheap *** manifold, it will probably crack and then there is downtime. BUt that doesnt look like a problem with the manifold you have picked out. You cna have a reliable setup on the budget you have. If you squeeze your budget to that 3K limit, you might be able to do some internal work too. I built my last turbo setup for around 1300 which included the a laptop and burning hardware to burn my own chips and a bunch of extras like vacuum manifold, gauge pod, extra gauges, etc.

Toroke

Which internals are most important to do? I'm not going to do it for a while, if at all. Depends on how fast I get money. I was just really worried about reliability, since this needs to last me through college. I mean worst case scenario, I spend a few grand on an old Civic hatch... but I'd prefer if this car didn't break.

So I'd need a physical burner? Where can you get those and chips for it?

Also, I forgot to mention, I have a connection to someone who knows a ton about this, but I'm really trying to do the most I can myself so I can learn.

Thanks for the help.

y7turbo

http://www.homemadeturbo.com
http://www.pgmfi.org
http://www.turbod16.com
read and learn.. thats how most of us did it..

Toroke

I'm a member of turbod16. I'm reading. And I'm learning.

Ricey McRicerton

You can definately break 14s on a sohc turbo non vtec setup.

I did a 13.8 on a long *** y7 tranny and shitty clutch on street tires.

Now I'm on a y8 tranny, a fresh Exedy organic and would hope for a 13.5ish @ 12 psi.

I'm on stock internals.
Port matched the y8 intake mani to the head and the head to the turbo mani. I'm on a Greddy td04h-15g kit, with the Type 24 front mount, E-Manage, and a handful of other goodies.

I've been boosting 8-10psi daily for the last 2 years on this setup with no problems whatsoever related to the engine or turbo.

EDIT: I know that really wans't all that helpful, so ask me specific questions as you come up with them.

Toroke

How about clutches? I've heard some good things and bad things. Flywheels too. Some people say get a new flywheel, but some say get your stock one lightened. Aftermarket lightweight flywheels can mess with your idle, or so I've heard. Once again, daily driver that needs to take some abuse.

Ricey McRicerton

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Toroke &raquo;</TD></TR><TR><TD CLASS="quote">How about clutches? I've heard some good things and bad things. Flywheels too. Some people say get a new flywheel, but some say get your stock one lightened. Aftermarket lightweight flywheels can mess with your idle, or so I've heard. Once again, daily driver that needs to take some abuse.</TD></TR></TABLE>

I run the Exedy organic on a stock flywheel. I love it.

viskii420

xtss ACT clutch kit
pro lite flywheel
s40 trany...
u dont relle need lsd cuz u project is not 200+hp but if u relle want good grip obx makes nice lsd for s40 trany..
dont abuse ur engine more than 7000 rpm
daily run max is 8-9 psi
track u can do it to 12 to 13 without bendin the valves or fry ur pistons..

Toroke

Right. Well between reading the archives and your responses, I've pretty much got all of my questions answered. Thanks everyone. I'll keep you updated. Now I've just gotta start buying the parts... Damn you, money.

Toroke

Right. Well between reading the archives and your responses, I've pretty much got all of my questions answered. Thanks everyone. I'll keep you updated. Now I've just gotta start buying the parts... Damn you, money.

silverboost

im runnin a d16y7 @7psi w/ stock injectors, walbro feul pump and 12:1 fmu, as for reliability ive been bossted for a month now and only probnlem has been a surging idle which was fixed, had nothing to do with the turbo, o yea and i smoked my bros vr6 passat, w/ chip, intake, exhaust