Jetta : 2.0 16V Turbo with a little bit of this and that.

Started off a while back. I bought the car from an old friend (Brendon Koch).
At the time the car was :
2.0 16V CLI 1993 model
Stock bottom end (2.0l 2E long block)
Head Stock KR 16V head
02A cable shift gearbox
T3/T4 hybrid turbo (AR.50 exhaust / AR.60 Intake side)
Car was a bit neglected and was running at 0.7 bar boost and making around 190Hp ATW.

I made a few small changes to some of the boost pipes and the exhaust and had the car tuned ... Power whent up to around the 230HP ATW mark and I was happy ... for a while :

Before










After








I decided to make a few changes to make the car to make it a bit more reliable and to make a little bit more power while at it. Goals when I started was a) Reliability b) 200HP at low boost and 200 KW at high boost.
I made the following changes:
Head was completely overhauled and flowed for turbo application (Work was done by Sarel Eloff 8V Performance)
Bottom end was rebuilt (semi forged pistons & crank), balanced and the flywheel was lightened.
ARP conrod bolts was added.
New Dictator management system.
Retuned
Turbo was rebuilt
Changed the turbo oil feed and return pipes.
New clutch stock friction material but the plessure plate is modified.

End result after quite a few teething issues.
Low boost 0.5 bar is good for +-200HP and 1 bar (high boost) is just on 300HP ATW.
It's quite a handful and a lot of fun. Best 1/4 mile time was 14sec on 0.8bar boost with ample ammounts of wheel spin (stock yokohama 195/15 tyres) and a 1 kilo speed of 223km/h (0.8bar)

Gearbox looking all pretty


Engin bay looking a bit better.
From this:

To:

















Future plans .... unsure. I need to replace the gearbox again (first one exploded this one the 2nd gear shynco is damaged. )
Whish list.. Wavetrack LSD and Semi's

Nice project joggiep and welcome to the forum!

You indicated a HP measurement for low boost @ 0.5 and a KW measurement at hight boost @ 1Bar ? What would the 1Bar HP be?

Do you have any Dyno Graphs? the power looks really good!

I whanted to make 200HP(low boost 0.5bar) and 200KW (+-270HP high boost 1bar) as a goal before I started with the changes to the motor.

I believed at the time that 200HP ATW will be a nice ammount of power for events like gymkanas and other track oriented events.It's not to mutch yet enough to keep things interesting. I take part in as many as possible events that are held (generally monthly) by the VW club of SA. The 1 bar high boost setting was/is there for mainly Dyno and maybe later drag racing events. I can go quite a bit higher with boost if I whant to 1.2-1.4 bar easily but the idea was if you look at my original post was reliable fun. I believe making more power while possible might sacrifice more reliability than I am confortable with, and judging by the 2 broken gearboxes in my garage .. 300HP is starting to push the reliability limits already a bit.

I ended up however making 200HP(150KW) ATW on 0.5 bar and 300HP(224KW)ATW on 1bar in the end so I made my goal power at low boost and I made my goal power with some change at high boost

I have quite a few dyno graphs.. I'll just need to dig them out.