[OBDream]

Hi there i30 lovers,

We have had our hatch for a few years now and I really enjoy driving it.

I have a 2010 CRDI U. It has injectors part number 338002A400, can anyone tell me the difference to part number 338002A900 are they bigger CC or do they operate differently?

The bosh rail pump mine is fitted with 331002A420 is the same pump fitted to other more powerful CRDI packages so I am assuming it can be used for higher outputs. I am looking at having the turbo (GT1544V) hi flowed approximate gains to 25psi from 19 stock (that's what they said), upgrade to 338002A900 injectors (if I will gain), heavy duty clutch, dump with muffler/res delete high flow euro3 cat, stock air box and ram plenum with K&N panel filter, full dyno tune.

What is the best combination to push the envelope within reason? I'm not trying to make a supercar! Surely this been done before? they are such fun to drive!

The internet is a wasteland of information in respect to the above and in Australia the information void is blunt and confronting in its complexity.

Can anyone point me towards somewhere where I can correspond with people who are willing and able to discuss this.

Cheers,

OBDream 

[mickd]

G'Day OBD,

 
Plenty of info there 
Can't remember who,  but,  there is someone who's done a bit of what you're thinking of.  Plenty of brains here as well. 
Those psi quotes are interesting,  19 & 25. I would have thought flowrate more helpful to diesel .

[Dazzler]

Welcome OBDream,

Yep, they are a fun car. I always worry though when someone wants to boost a 9 year old car. Components will be starting to wear and get tired. You could end up spending quite a bit of money then cause a premature mechanical failure. The other thing is with performance enhancements you should then look at brake enhancements and suspension enhancements.. Sometimes in this situation you would be better either spending the money on some cosmetic enhancements instead or saving up some money that you would have spent on these upgrades and trading her in 6 or 12 months on something with more performance out of the box.

I know I sound like a party pooper and may get shouted down by the boy racer parade but someone needs to say it. 

[OBDream]

Thanks for the welcome Daz, Mic,

I understand your point of view Dazzler, I am not worried about expensive components. I just missed one at auction it went for $1000 I should have put 1200 on it!. Genuine parts can be found in Korea via Ebay. Unless I take it on the track the brand new Ultima rotors and Bendix pads seem to do just fine. Anyone who knows these cars well knows they stop good.

Yes flow rate is important, preferably you want as little restriction as possible hence the dump pipe hi flow cat and straight through. If I start making the exhaust side of the turbo bigger as well I might as well make a custom turbo header and buy a bigger turbo but I'm not chasing 800Nm. I was told by turbo builder he could increase the compressor wheel size whilst keeping same size exhaust wheel so as not to increase lag. Said it would give about +18-20% output max

I'm hoping for figures around 115Kw from 85Kw stock and around 360nm from 255Nm stock so not looking to go stupid.


 

[nzenigma]

 I always worry though when someone wants to boost a 9 year old car. Components will be starting to wear and get tired.

Party Pooper.!  This engine is bullet proof. Look at the MILES some of the poms are getting out of her.

[mickd]

Okay,
 so more intake volume, thus more exhaust, more pressure to spin snail etc etc.

[mickd]

 I always worry though when someone wants to boost a 9 year old car. Components will be starting to wear and get tired.

Party Pooper.!  This engine is bullet proof. Look at the MILES some of the poms are getting out of her.

Not just the poms, where's that red one gone      

[Dazzler]

 I always worry though when someone wants to boost a 9 year old car. Components will be starting to wear and get tired.

Party Pooper.!  This engine is bullet proof. Look at the MILES some of the poms are getting out of her.

But are not usually modified ones... 

[OBDream]

 Brilliant engine. Same block through multiple platforms.... same turbo across multiple brands....

[nzenigma]

But are not usually modified ones... 

  A PD is just a modified 1.6 FD. 

[Dazzler]

But are not usually modified ones... 

  A PD is just a modified 1.6 FD. 

Yeah maybe, but I don't think they've increased the output of the 1.6 CRDi version much if at all. ..  (I could agree with you, but then we would both be wrong..) 

[nzenigma]

Brilliant engine. Same block through multiple platforms.... same turbo across multiple brands....

 

G'Day OBD,

Can't remember who,  but,  there is someone who's done a bit of what you're thinking of.  Plenty of brains here as well. 

That was before my time here too. @Dazzler may point you in the right direction.

This sounds like a brilliant project, that I have also thought about, but never found the time to research or to get hands dirty on.

When you know exactly what parts you need , we can open "Our Gerard's" cell door,  he lives in there and has memorised the part number of every component Hyundai has ever used or made. @tw2005

There's a lot of info on the web , however it is generally buried under a ton of bullshit deposited by mere keyboard warriors.

 Been there, done that, with my Z3 engine upgrade.
 Eventually found confirmation that my theory was correct after reading countless American threads that were typically full of motor-mouth drivel  . The single, sane, post I needed was in a topic to nowhere, on page 22 !

and yes after 6 weeks grind in my workshop, the 'Bimmer Z3/330iM' fired up perfectly.

Best of luck

[mickd]

G'Day OBD,

 
Plenty of info there 
Can't remember who,  but,  there is someone who's done a bit of what you're thinking of.  Plenty of brains here as well. 
Those psi quotes are interesting,  19 & 25. I would have thought flowrate more helpful to diesel .

I'm 85% sure they have a silvet FD with  HF Cat, no muffler etc, altered airbox  and live in Sydney . Brain has been off the last couple of days    and its currently sudetracj by snapping 1/2 a tooth off. 

[OBDream]

It sounds mint with HF cat and straight through, and I have not even done the dump yet. I immediately noticed fuel economy gains from the exhaust change without tuning it. If I can up the output of the stock turbo slightly and put slightly bigger injectors in it then map it on a dyno I think I will have a nice little sporty hatch. Wont ever be a golf killer but with the roof rack and the Perspex headlight & bonnet stone guards it certainly wont be expected.

[mickd]

@OBDream
 There's a post in the "Engine Bay section" by electroman5000 with heaps of info re: GD 1.6D
F##k, still can't remember who   

[Dazzler]

I'll put my thinking cap on @mickd

[Paolo39]

I have a 2010 CRDI U. It has injectors part number 338002A400, can anyone tell me the difference to part number 338002A900 are they bigger CC or do they operate differently?

Beat me I do not see the difference. From Bosch web site:

HYUNDAI 33800-2A900:

Description
Part number 0986435186
Designation Injector, CR system
Production discontinuation -
Type formula BX-CRI2
Product information Combustion chamber seal ring pre-assembled
Exchange no. 0986435186
Injector type Magnet Injektor
Combustion chamber sealing vormontiert
ISA IMA (encoded) IMA
Pressure stage 1.600


HYUNDAI 33800 2A400:

Description
Independent aftermarket part (IAM) 0986435152
Designation Injector, CR system
Production discontinuation -
Type formula BX-CRI2
Product information Combustion chamber seal ring pre-assembled
Exchange no. 0986435152
Injector type Magnet Injektor
Combustion chamber sealing vormontiert
ISA IMA (encoded) IMA
Pressure stage 1.600


Looks the same on the paper.

[sundiz]

They offer ecu programming to your model with 104kW and 300nm. And those values come with stock parts. Bigger/modified turbo should help. One question is the fuel pump. Can it produce enough juice to the desired power?

[OBDream]

"One question is the fuel pump. Can it produce enough juice to the desired power?"

That is a good question.

The same pump part number is used on more powerful D4FB units

The problem is....Do the other injectors have the same spray pattern? Are they identical injectors but different part numbers because different vehicle model?

Do all D4FB have exactly the same piston shape? Does one piston kit replace all D4FB?

I suspect the injectors may all be the same for the D4FB

The 1.7 crdi I believe is a D4FB derivative with an extended stroke?

[sundiz]

I have not seen any projects where the hyundai engine has been pumped up. With diesel the tune simplidied when compared to petrol engines. There are usually only 2 variables: air and fuel. With bigger/modified turbo you will get more air. The amount of fuel depends on the fuel pump and injectors. I would assume that the OEM pump would work with decent power, but there is not great amount of information about hyundai engines. All I know that there has been 1.5 litre crdi getz that got about 150hp with stock parts.

Fuel pump has been knowm issue with mercedes. 220 or 270 cdi engines have required the fuel pump of 400cdi engines to be able to produce enough fuel for higher tunes.

One of the issues with extreme diesel tuning is the pressure in exhaust manifold. With max tune the pressure might get too high and would need better manifold and larged exhaust pipe. But I would guess that would not be the problem with your desired power. Only heard of that causing issues when they want to take over 500hp from old 3 litre diesels.

[sundiz]

Of course the tune will help, but my personal experience with hyundai fuel pumps has not been good. I got limp home modes when I changed 3rd party fuel filter. I got error messages from low fuel pressure. With OEM filter the car has been working fine. Based on my experience the production of fuel is not that impressive if 3rd party filter can get the car in to limp mode home.

[nzenigma]

Of course the tune will help, but my personal experience with hyundai fuel pumps has not been good. I got limp home modes when I changed 3rd party fuel filter. I got error messages from low fuel pressure. With OEM filter the car has been working fine. Based on my experience the production of fuel is not that impressive if 3rd party filter can get the car in to limp mode home.

@sundiz

Mate at first I thought that was a reasonable proposition.
But had a re think.
Your filter is between the LP tank pump and the HP pump .
The Oz vehicles do not have a tank pump and to the best of my knowledge it is the same HP pump as in Europe models.
It would seem the tank pump is probably employed to overcome cold fuel conditions.
The limp mode was probably due to that pump being weak or affected by the filter.
In the case of the OPs questions, adding a tank pump may overcome the assumed  need for more fuel

[mickd]

Dont know much but, previous work vehicles;
80 series landcruiser, mitsu triton tdi, ford courier tdi, ford ranger tdi all had an adjustment to increase fuel flow on pump. All had a protective steel cover that need to be removed first. Had to ask diesel specialist where it was on ranger.
Courier had fuel increased and a larger diameter actuater fitted on turbo pressure release. Blew two gearbox mainshafts somehow  .

[sundiz]

That is good to keep in mind. If/when there are 2 pumps, both of them need to be sufficient for the desired amount on fuel. Some guy build 700hp 3litre diesel. He had 2 transfer pumps and highly modified high pressure pump and injectors.

[OBDream]

That is good to keep in mind. If/when there are 2 pumps, both of them need to be sufficient for the desired amount on fuel. Some guy build 700hp 3litre diesel. He had 2 transfer pumps and highly modified high pressure pump and injectors.

 That's nuts, and a crdi Getz with 150hp is nuts too what are the torque figures? 

[mickd]

That is good to keep in mind. If/when there are 2 pumps, both of them need to be sufficient for the desired amount on fuel. Some guy build 700hp 3litre diesel. He had 2 transfer pumps and highly modified high pressure pump and injectors.

 That's nuts, and a crdi Getz with 150hp is nuts too what are the torque figures?

Torque is farking heap !!

[sundiz]

 That's nuts, and a crdi Getz with 150hp is nuts too what are the torque figures?

They measured at first tune 250nm, but they added little bit of torque after that. They estimated to be approx 300nm now. A bit of challenging drive with that vehicle mass and torque during winter with low grip.

[nzenigma]

 A bit of challenging drive with that vehicle mass and torque during winter with low grip.

  This months understatement?

[OBDream]

So, after many hours of searching and talking to shops around the place I have decided to go with a tuning shop which has quoted me 130Kw and 450Nm with a 33psi stock turbo rebuild, on top of already fitted dump pipe, straight through exhaust with hi flow cat and for now a stock intake with panel filter.
Also 17x7.5jj's +48's fit pretty nice and fill out the guards with plenty to spare

Will never be a golf killer but sure as heck wont be expected!

I believe the same shop has a very very nasty Getz!

Will never be a golf killer but sure as heck wont be expected!

Depends on the Golf, GTi is nothing special which the i30 N betters for a considerable amount less, whereas the Golf R is in another league

Which tuner are going with?