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How to TDI a Karmann Gipsy

by

Tudor Morgan

 


 

Additional Information for converting a 90ps TDI to a 110ps TDI


The following operations will have to be undertaken

  • Fit uprated / stronger VW big end shells

  • Fit uprated big end bolts

  • 110ps TDI turbo and associated pipework required

  • 110ps brain control unit required

  • Additional cabling on computer required




  • TDI engine 90ps useful Data

    Compressions

     

    New engine

    25 to 31 bar

    Worn engine

    19 bar

    Note temp should be at least 30 degrees C

    Thermostat

    80 degrees C

       

    Pump timing

    0.70 mm

       

    Big end bolt torque

    30 nm + 90 degree

       

    Ring gap

    0.20 to 0.40 new Top and second rings

     

    1.0 to 1.20 worn

     

     

     

    0.25 to 0.50 new Oil rings

     

    1.00 to 1.20 worn

       

    Cylinder Head

    40 nm Step 1

     

    60 nm Step 2

     

    then a 90 deg turn

     

    then another 90 deg turn

       

    Oil Pressure

    200 rpm 80 deg C 2.0 bar

     

    Max 7.0 bar

     

 

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