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 Post subject: Swift 1.6 GTi Turbo - a build with lots of pictures
PostPosted: Mon Jun 13, 2011 5:21 am 
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Location: Hungary - Europe
A friend of mine asked me to share the history of his upcoming build with the community of redlineGTi. So the car - unfortunately- is not mine.

He has been dealing with Swift GTis for more than 10 years he has assembled dozens of GTi engines from their parts so far. Some years ago he decided to build an engine that was unique here in Hungary that time - an 1.6 GTi. This engine was built into a silver mk4 chassis that was completely shaved. It was a real sleeper. :D The car could run in 15,4 secs down the 1,4 mile without putting anything out of the 900+ kgs chassis. (with the driver and fuel it was above 1 ton) and on street tyres. The engine was stock apart from the change of the block - the ECU, cams were all stock. I think that is not that bad.

Now he wants to build a 1.6 GTi engine which is going to be turbocharged. In fact he is building two - one goes into that mk4 silver chassis and is going to be FWD and the other is into a red one and is going to be AWD. He is building completely new engines now, the naturally aspirated one is going to be put on a shelf. He does not want to bother that good engine.

I would like to share some pictures of the car in its naturally aspirated state:

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The naturally aspirated 1.6 engine:

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An interior shot:

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Last edited by Z GT-i on Thu Jun 16, 2011 6:12 am, edited 4 times in total.

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 Post subject: Re: Swift 1.6 GTi Turbo
PostPosted: Mon Jun 13, 2011 5:47 am 
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Almost everything arrived this week so that he can start the procedure of assemblies. Pictures will come later from time to time as the build goes ahead.

Some Information about the engine:

- the block will be a standard 1.6 block with its own crank
- rods are Pauter rods
- pistons are forged Wiseco Honda D16 pistons (compression will be 9,5:1)
- the turbo is a Garrett GT2554 turbo
- the manifold is a custom made one
- ECU is a Vems - I do not know if you are familiar with this brand, so here is the site of the company : http://www.vems.hu/ Just a piece of info: during the King of Europe event in 2007 a Vems powered racecar could repeat 8,6 sec runs on 402m.
- ARP studs
- the 560cc injectors of the Lancer Evo
- Multi-layered steel gasket

In the following pictures you can see an "engine stand" which was made by my friend to make the work of the exhaust company easier. They made the manifold following the instructions of my friend. The engine in the picture is not the engine that is in the build it is just an empty 1.6 block with a GTi cylinder head bolted to it.

Unfinished manifold:
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And the finished one:
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And a picture of the stickers that we got from the companies:

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Hopefully. more pictures will come tomorrow.

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Last edited by Z GT-i on Tue Jun 21, 2011 4:52 am, edited 1 time in total.

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 Post subject: Re: Swift 1.6 GTi Turbo
PostPosted: Mon Jun 13, 2011 7:23 am 
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Location: england
nice manifold!


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 Post subject: Re: Swift 1.6 GTi Turbo
PostPosted: Mon Jun 13, 2011 11:45 pm 
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Nice manifold. Why using such a small turbo? I have a gt2554 on a 1.3 and it spools up really quickly, but on a 1.6 might run out of puff a little early for you! Great little turbo though.

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 Post subject: Re: Swift 1.6 GTi Turbo
PostPosted: Tue Jun 14, 2011 5:51 am 
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Thank you for your comments!

FlyingGrape: Yes, you are right, there are bigger turbos on the market that he could use but my friend thought that this Garrett GT2554 should be enough for street use. He does not want to race with the car. Reliability and durability are also important for him. Because of the characteristics of the 1.6 block the revlimit will be 7000-7200 and he thinks that this turbo will flow enough on the way to that revlimit. On the site of the Garrett turbos the company says that using this turbo can result a maximum of 270 horsepowers. We will be very happy if we reach that amount of horsepowers on the crank. If the turbo is not enough, my friend will try to change to a bigger one. :) The picture will be clearer when the car is ready.

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 Post subject: Re: Swift 1.6 GTi Turbo
PostPosted: Tue Jun 14, 2011 6:16 am 
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And now, as promised yesterday, here are some more information and pictures.

Transmission: the naturally aspirated car has a gearbox with the gearset of the Swift Sport + a Torsen LSD now. This remains the same in the turbocharged car but there is an exception: the final drive ratio will be changed from 4.4:1 to 3,5:1.

The bearings are brand new SGP ones. My friend thinks that amongst the bearings that can be bought here in Hungary these are the best. You can also buy Clevite and King and etc ones but our experiences are not so good with them.

Some parts on the floor - not all the parts just a bunch of them- :

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 Post subject: Re: Swift 1.6 GTi Turbo
PostPosted: Tue Jun 14, 2011 6:32 am 
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As I said yesterday evening, the procedure of assemblies started. The blocks were machined to suit the new rods. You will see the changes in the pictures.

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 Post subject: Re: Swift 1.6 GTi Turbo
PostPosted: Tue Jun 14, 2011 6:50 am 
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His block is from a Vitara which was only driven for 40000 kms, so it is in extremely good condition. He has made some modifications to it.

The first one is:

On some of the pictures you can see a short (about 8-10cms long) yellow pipe built into the block. That was made in order to lead the gas fumes out of the block. This modification has not been finished yet - only the pipe has been built in.

The second one is:

He made some modifications in order to be able to build in the oil jet system of the BMW. It is built in because of the strong pauter rods' shape - as they do not have the holes for the oil on them, they do not allow the flow of the oil as the factory rods do. You will see the modifications clearly in the pictures:

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 Post subject: Re: Swift 1.6 GTi Turbo
PostPosted: Thu Jun 16, 2011 5:24 am 
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rod + piston + oil jet

The oil jet fits just right:

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 Post subject: Re: Swift 1.6 GTi Turbo - a build with lots of pictures
PostPosted: Thu Jun 16, 2011 4:14 pm 
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All the jets were built in yesterday evening:

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 Post subject: Re: Swift 1.6 GTi Turbo - a build with lots of pictures
PostPosted: Thu Jun 16, 2011 4:19 pm 
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rods + pistons + SGP bearings:

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A little comparison:

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There is the little hole that is missing on the pauter rods (and that is usually missing on the forged rods):

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Last edited by Z GT-i on Thu Jun 16, 2011 4:33 pm, edited 2 times in total.

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 Post subject: Re: Swift 1.6 GTi Turbo - a build with lots of pictures
PostPosted: Thu Jun 16, 2011 4:22 pm 
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Feel free to leave a comment if you had any tips, ideas, suggestions!

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 Post subject: Re: Swift 1.6 GTi Turbo - a build with lots of pictures
PostPosted: Fri Jun 17, 2011 8:53 am 
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Pretty keen to see the end result.

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 Post subject: Re: Swift 1.6 GTi Turbo - a build with lots of pictures
PostPosted: Fri Jun 17, 2011 4:16 pm 
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Thank you southy! :)

Unfortunately he can only work on the project in the weekends because of his job. :(
New pictures will come in 1-2 days!

To be honest I am also very keen to see the results, especially to see the differencies between the two cars - for as you can see in the pictures that I posted of the parts, the AWD's engine management system will be a motec and it has a different turbo + manifold.

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 Post subject: Re: Swift 1.6 GTi Turbo - a build with lots of pictures
PostPosted: Sun Jun 19, 2011 6:37 am 
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The following pictures show the first half of today's work.
There were some problems with the jets so he had to work on them for a few hours.

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 Post subject: Re: Swift 1.6 GTi Turbo - a build with lots of pictures
PostPosted: Sun Jun 19, 2011 6:50 am 
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When this work got finished he could start the second half of today's work. His aim was to assembly most of the bottom end of the engine till evening.

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The braces have also been installed:
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Next step: Installing the pistons

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 Post subject: Re: Swift 1.6 GTi Turbo - a build with lots of pictures
PostPosted: Sun Jun 19, 2011 6:54 am 
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Finally, two pictures of the fruit of his hard work:

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 Post subject: Re: Swift 1.6 GTi Turbo - a build with lots of pictures
PostPosted: Tue Jun 21, 2011 1:10 pm 
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Looking good, has any work been done to the head?

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 Post subject: Re: Swift 1.6 GTi Turbo - a build with lots of pictures
PostPosted: Tue Jun 21, 2011 4:52 pm 
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As far as I know, not yet, Ben. He says that a lot of pictures will come today or tomorrow. They will be taken during working on the cylinder head. :wink:

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 Post subject: Re: Swift 1.6 GTi Turbo - a build with lots of pictures
PostPosted: Tue Jun 21, 2011 5:11 pm 
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Awesome good to see its progressing well :wink:

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