Hello.
Look at my wife's GTD (dark) - 1,6TD, 80hp, about 0,5 bar boost and my 1,6TD, ?ps, about 1,7 bar boost and adjusted to more fuel.









And here You can watch the movie - accelerate MK2 from factory and adjusted. My boosted makes nice, black smog, but only in full load. When I drive easy then MK2 don't generate any smog. Accelerate is about 6 sec to 100km/n - I think it is good without any mechanical adaptation - only adjusted wastegate, full load screw and boost pin.
From factory - http://videos.streetfire.net/video/EBA481C6-5A53-4405-823A-8920A809431B.htm
Adjusted - http://videos.streetfire.net/video/81E6024D-BE98-4498-90F3-B3147032A3BA.htm
Adjusted but little light video from 0 to 190 km/h (MK2 adjusted can drive 200 km/h but in front of me any car coming and road was very narrow) - http://videos.streetfire.net/video/B979268E-D48C-48BC-9587-66E46E8ACCB8.htm
Boost, 3rd, 4th and 5th rear - http://videos.streetfire.net/video/78E55D0B-E67F-402D-B588-0CD148CCEF2A.htm
Nice watch...

Very nice.

Which way does the cooling air flow past that GTD intercooler? left to right or right to left?

I wish the GTD had made it over here, I want that IC setup!

After your tuning including 25psi boost, I agree that you hit 0-100kmh (0-60mph) in about 6 seconds ... no slouch there!  I doubt any naturally aspirated 8v GTI as streetable as yours could keep up with it.

Do you know how much this car weighs?  Your turbo looks to be very responsive - is it the stock K14?  What exhaust setup are you running?

PS - just by eyeballing the video timer of the stock acceleration, it looks like when stock it did 0-100kmh in about 11 seconds.  Nice job with the car, and thanks for sharing the pics and videos!

(Welcome to the GTD Forum by the way! )

Hello.
My english isn't good but I think You understand me.
I have this MK2 obout 2 years. It was 80hp, like my wife's MK2. First adjust was a turbo and full load screw. Afret this - boost grow up to 0,7-0,8 bar. Some summer day I made race on the higway with ford focus 1,8 tdci - too much RPM (5000rpm) in too much time. 30 minutes of faith with engine temperature about 3/4 scale - this made a defect of engine. After this my engine sound was like, hmm, i don't know what...
Four new pistons with larger dimension and polished up engine block - after this my engine is like new. New injection nozzles sd274 "monark diesel", new valve seals, head gasken and of course head screws.
After 1500 km I adjusted again boost in wastegate - 1,1bar. Next full load screw adjusted - 1,4bar bost - more fuel=more exhaust gas=more turbo. Next boost pin adjusted - now 1,7bar on 4th and 5th gear on full load. I think that's enough. Safety speed long time run is about 170 km/h. Higher speed for long run need an oil cooler (not oli/water cooler like is in stock GTD) and biger water cooler. And of course intercooler in front of car - not like in original idea VW engineers.
I think this 6 - 7 sec from 0 to 60 mph isn't really true - look and concentrate on wheels in my MK2 - they are a little smaller than original - 14 inch whells with 175/50/14 tyres - really low. It makes of course lower max speed but higher accelerate. So if You see 100km/h on my speedometer - really is about 90km/h - I think
I don't remember what a turbo is in my car - of course it's a stock turbo - tommorow I make a photo and paste here. Exhaust is stock too. I don't want make a more adaptation in thi car - I dream about MK2 1.8 syncro (all whells drive), then swap engine to 1.9 TD (IDI of course) and then i made many more adaptation like bigger exhaust, bigger intercooler, oil cooler and many more... In a future...

Very good to watch the videos. Thanks!
Congrats on your tuned machine as well. It rolls hard!  :twisted:  But if I were you I would stick to the 1.6L engine instead of a 1.9 swap as you are planning. Doesn't it rock to have a 1.6L diesel that smokes away TDI's and gassers?!  :twisted:  :lol:
That stock GTD did also impress me for its acceleration.  :wink:  It's gotta be f*ckin' fit, despite unaltered!

gotta do something about head gaskets,,like a metal one,then let it boost to the moon,,i had head studs,,it would always bury a 30 psi guage,somewhere around 35 or so i think,,fuelkilled it,not boost,although even w/ studs i still popped a few gaskets

must be Garrett T2

Speak for yourself, this was a warm winter. And I'm about 20 miles from you...