1997 B4V 1Z Grocery Getter Build

kooyajerms

grocery getter
Joined
May 5, 2004
Location
Pomona, Southern California
TDI
97 B4V (mine), 11 x5 35d (hers) 04 V10 (that one you want), 2014 Q7 (mom's) 74 Shasta 1400
she lives again post#606
Montclair, CA 12/1/2012
226whp/380ft-lbs

Montclair, CA 5/14/2012
203whp/320ft-lbs

Las Vegas, NV 4/21/2012
205whp 344ft-lbs

Montclair, CA 12/14/2011
194whp 319ft-lbs

194whp 290ft-lbs on the conservative Superflow(or actual whp as some people say).
ohio

Bad dyno runs from the GTG

194 dyno run
dyno run gauges look at that tune!
last dyno run
-Torque steer is real, oh yes I will be learning how to drive again from what Matt says.
-Tires break loose 1st 2nd 3rd and maybe 4th.
-Car doesn't smoke unless you go wot at 1800rpms, and then it clears up as it spools. Smoke on the dyno was heatsoaked at 140*F IAT and the turbo still cleared it up.
-Boost is 28psi and spools up at 2000rpms. Go GTB!
-EMPs will go 4psi higher than max boost at most and be 1:1 for the most part. The turbine is the restriction once the rpms are up past 4500.
-EGTs are maxing out at 1350*F. Room for fuel and the lift pump
-Still breaking in all the parts, but Matt was getting 41mpg on break-in oil I believe.
-Mark's tune is doing a great job of keeping the power up, check those gauges.
Comparable dyno
This is loudspl's old dyno 1856 with R520's and 11mm pump so similar fueling and pretty similar engine other than being an ALH. 164whp 273 ft-lbs. I think Eric's got sick fuel going into it now and puts down 174 on the same dyno.
Why did I send it to Ohio?
Not many TDI gurus in Los Angeles. Harvieux is great but wasn't interested in the modded beast, and I had the jeep turbo on there already. Didn't want to use VWSpecialties, so I looked at my options and thought of going to Fixumhaus because it was the next closest who would do this specific build. But instead, I went to who I knew. Whitbread Innovations. Matt's been feeding the mod hunger by even providing me the option for the gt2056v on the b4. Matt could fabricate, and fit, and build, and fix and make the beast the way I wanted. Mainly, I could trust Matt. So it cost me almost $1000 just to send it to Matt. I'm in Los Angeles and sent my car 2500 miles! That's how dedicated I am to these TDI's!
Malone Tuning
1Z engine
80mm ASV pistons
Rosten Rods
Ported head
HD valve dual springs from Shortysclimbin
Eurospec Engine Girdle
ARP2000 Headstuds
Colt Cam Stage 2
11mm VW Reman Pump
Bosch764's flowing some great numbers! Thanks Frank!
GTB2056VK from Audi Q7, custom comp housing and vacuum actuator
4-1 Exhaust manifold
Custom Intake Manifold
2" IC Piping
Custom 3" Turbo Inlet Pipe
Crankcase Breather to Exhaust
Cat Filter with thermo t delete
BFI Stealth Poly Motor Mounts
2.5" Downpipe and Turboback Exhaust with Dual Exit Tips (Moroso Muffler, with optional cat vbands)
02A Transmission with 02J shifter conversion
Peloquin LSD
SBC Stage 3 Clutch
.658 5th gear turning 2200 rpms at 75mph.
Jeremy


Thanks to Biochoppers, VWMikel@TDTuning, Boraparts, IDparts, Franko6, Athreetdi, shortysclimbin, NoJoke, im570rm, rub87, Whitbread, and Mark@MaloneTuning
 
Last edited:

kooyajerms

grocery getter
Joined
May 5, 2004
Location
Pomona, Southern California
TDI
97 B4V (mine), 11 x5 35d (hers) 04 V10 (that one you want), 2014 Q7 (mom's) 74 Shasta 1400
1997 B4V TDI 1Z Grocery Getter Build

Pictures
What I bought
The original B4 bought in April of 2008, Daytona Beach Florida and driven back to Los Angeles.
How it was modded last year
gta2056v
Why did I do the build?
Engine Runaway. The reason for a full engine bay update.

Longblock with accessories. Shiny new pump =)

engine bay

Turbo
modified comp outlet on GTB2056VK with one of the first Whitbread intake manifolds, pre-hype!

Maf Delete Turbo Inlet Pipe

4-1 header with emp and egt bungs




Custom Vacuum Actuator ;D
 
Last edited:

kooyajerms

grocery getter
Joined
May 5, 2004
Location
Pomona, Southern California
TDI
97 B4V (mine), 11 x5 35d (hers) 04 V10 (that one you want), 2014 Q7 (mom's) 74 Shasta 1400
1997 B4V Passat 1Z TDI Grocery Getter Build

Downpipe to the flex over the rear beam



Matt's favorite dual exit exhaust


My old same side FMIC with 2" IC pipes from Whitbread. Matt's special sillicone couplers and tclamps that never pop off. Woot 28psi!

2" IC pipe behind the battery

2" inlet to custom intake and turbo outlet pipes

We did the 02J shifter conversion Took Matt some time, but the shifting is nice and tight. Hopefully even better than the DG short shifter that was original on the 02A. Shifting is even a bit short, without any mods. Matt was surprised, and didn't need to modify it.
Motor Mounts
BFI Stealth Kit 50a shore hardness poly motor mounts.
We replaced front and back and left the transmission mount stock oem.
Wish I didn't have to go Poly but the engine was very angry.
http://www.youtube.com/watch?v=6UJZ4clV7Y8. Sits nice and tight now. There is some vibration, but oh well, had to do it.
Later additions


Changed the wheels to some Porsche seven slots
http://forums.tdiclub.com/showpost.php?p=3609036&postcount=325
http://forums.tdiclub.com/showpost.php?p=3609036&postcount=368
Isspro gauges
http://forums.tdiclub.com/showpost.php?p=3609036&postcount=363
 
Last edited:

NewTdi

Top Post Dawg
Joined
Jan 15, 2004
Location
NorCal
TDI
2003 Bora, Reflex Silver
Wow, what a beast! I'll drive down to SoCal just to check it out! Hopefully you'll make it up here for our Fall BayFest on September 24th and 25th. Nice build indeed ...
 

Growler

Got Soot Vendor
Joined
Nov 24, 2003
Location
Millersport, Ohio
TDI
Schmutz, 2015 Golf Sportwagen DSG & Schnurren, 2001 Golf GL 2 door 5M
Congratulations Jeremy & Matt. lots of hard work has paid off!
 

Keebler145

Veteran Member
Joined
Jun 29, 2008
Location
Niles, Ohio
TDI
Jetta MKIV 2000, 2003, and MKV 2006 PD DSG
WOOOHOOOOO!!! awesome dude!


that custom actuater is rather interesting haha
 
Last edited:

Nash_TDI

Veteran Member -TDIClub Enthusiast
Joined
Sep 3, 2002
Location
Louisville, ky
TDI
2000 Silver Jetta TDI
Very impressive guys. Stock valves? Why no lift pump yet, couldn't get a fuellab one in time?

Would love to see numbers on the intake manifold, before and after. I have heard rumors about it too.
 
Last edited:

kooyajerms

grocery getter
Joined
May 5, 2004
Location
Pomona, Southern California
TDI
97 B4V (mine), 11 x5 35d (hers) 04 V10 (that one you want), 2014 Q7 (mom's) 74 Shasta 1400
Growler- Thanks Aaron, it's been a wild trip, still gotta pick it up!

Newtdi- Thanks Andrew, now you know why I couldn't make the gtg.

Keebler145- Yeah, i'll keep salt off that actuator rod and it should last me a while, because no one else is gonna make that one =p.

Nash TDI-Fuel lab got sent yesterday, and stock valves, but the stronger springs.
 

IndigoBlueWagon

TDIClub Enthusiast, Principal IDParts, Vendor , w/
Joined
Aug 16, 2004
Location
South of Boston
TDI
'97 Passat, '99.5 Golf, '02 Jetta Wagon, '15 GSW
Looks great, nice clean install. No surprise there. What kind of dyno was it? Can't tell from the video.
 

kooyajerms

grocery getter
Joined
May 5, 2004
Location
Pomona, Southern California
TDI
97 B4V (mine), 11 x5 35d (hers) 04 V10 (that one you want), 2014 Q7 (mom's) 74 Shasta 1400
A superflow eddy current I believe.

If chippednotbroken sees this, my car was having very similiar symptoms as his build. emps were rising, egts went up an extra 100 degrees, boost was lagging. Put the muffler on instead, and it went back to being happy... Don't know what it is with big turbos and the cats.
 

Rub87

Top Post Dawg
Joined
Dec 10, 2006
Location
Belgium
TDI
Ibiza '99 90HP
looking good.. any oinfo about smoke or afr, dyno with one big roll or two small ones?

I'm trying to make a guess about the turbo performance =)
 

dieseleux

Théoricien -TDIClub Contributor
Joined
Nov 14, 2006
Location
Pas assez loin pour vider ma tank!
TDI
Jetta TDI 02
Very good number and beautifull setup!!!

I very happy to see this on 1Z, you make in real my evaluation i think to do on my AHU at top of tunning (Aprox 190-195Whp at 30psi on my GTB2056VL)
Thumb Up!



Dieseleux
 

NewTdi

Top Post Dawg
Joined
Jan 15, 2004
Location
NorCal
TDI
2003 Bora, Reflex Silver
Newtdi- Thanks Andrew, now you know why I couldn't make the gtg.
... now you know that there is a racing session at Infineon Raceway on Saturday the 24th for our GTG! You better be there with your white beast :D ! Ia m observing only since my clutch is slipping ;)!
 

Mark@MaloneTuning

Vendor , w/Business number
Joined
Sep 24, 2003
Location
Blaine, Washington and Vancouver, British Columbia
TDI
'14 GSW TDI, '11 Golf TDI, '97 Golf Variant Syncro 1.9L TDI, '96 Golf 1.9L ASV TDI, '93 Eurovan Westfalia 1.9L TDI, '09 BMW 335d, '17 BMW 328d
194whp is great considering the 764s and no smoke @ 28 PSI. Another car did 164whp on the same dyno with a 1856 turbo @ same boost (IIRC), R520 nozzles, and a very aggressive tune (lots of smoke). This is a testament to the efficiency of kooyajerm's car.

Look forward to bigger nozzles and we can cut back the off-boost smoke at ~1800 RPM WOT. Kudos to Whitbread and others who made this possible!! :) You need to move to B.C. so I can go for a ride ;)
 
Last edited:

Digital Corpus

Top Post Dawg
Joined
Mar 14, 2008
Location
Ontario, California
TDI
'97 B4 w/ 236K mi body, 46K mi soul
Congrats Jeremy! Glad to see your B4V nice and spiffy. What you've done makes a chip and nozzles seem like child's play. When is it going to be home again?
 

Mark@MaloneTuning

Vendor , w/Business number
Joined
Sep 24, 2003
Location
Blaine, Washington and Vancouver, British Columbia
TDI
'14 GSW TDI, '11 Golf TDI, '97 Golf Variant Syncro 1.9L TDI, '96 Golf 1.9L ASV TDI, '93 Eurovan Westfalia 1.9L TDI, '09 BMW 335d, '17 BMW 328d
Dump more fuel and turn up the boost!!!
Right now his 764s are maxed out. The only way to add more fuel is to upgrade the hardware. He's waiting on larger nozzles (I believe Franko6 is working on something) and a lift pump.
 
Last edited:

Keebler145

Veteran Member
Joined
Jun 29, 2008
Location
Niles, Ohio
TDI
Jetta MKIV 2000, 2003, and MKV 2006 PD DSG
didn't know he was running pp764s.... I really was debating on getting rid of my 764 or not. With those numbers I don't know if I will or not
 

devonutopia

Top Post Dawg
Joined
Dec 1, 2003
Location
Devon, U.K
TDI
PD300 Skoda Fabia
Nice - I gotta get me one of those MAF delete pipes as I am sure my current tune does not use the MAF at all. Be good to remove that restriction from my air intake system.
 

Farfromovin

Torque Addict
Joined
Apr 9, 2005
Location
Ventura, CA
TDI
03 Golf 2dr- PD150 6m
Jeremy, can you post the graph? I'm very interested in seeing the torque curve on the 2056vk. Also, do you plan on switching to a 4bar map sensor for a few more PSI? AFAIK, the 2056vk can probably run 30 to maybe 32 psi? Any thoughts there? Shoot, you could just leave it as is and have a healthy, smoke free 200whp wagon that has a healthy safety margin (probably wisest lol).
 

kooyajerms

grocery getter
Joined
May 5, 2004
Location
Pomona, Southern California
TDI
97 B4V (mine), 11 x5 35d (hers) 04 V10 (that one you want), 2014 Q7 (mom's) 74 Shasta 1400
Exactly what I'm thinking Phil. Didn't want to go 4 bar, have higher pcps, change the doniol =p, and all that. Give me 230 dynojet whp and I'll be happy. I'm not that far off.

Matt can't get to a computer till later. We are gonna have to wait on the graph. He said the curve was pretty nice, although from 4k and up the turbine is actually restricting, Mark did a great job on the tuning portion.
 

Farfromovin

Torque Addict
Joined
Apr 9, 2005
Location
Ventura, CA
TDI
03 Golf 2dr- PD150 6m
Well, maybe your cylinder head is just that good. I wouldn't think that the GTB2056vk would be the choke point at 230 dynojet-hp... If I can ever get my 17/22 to die, I gotta pick a nice replacement and this turbo is on the list. From your description so far, it seems to spool quicker than the 17/22!
 

glitdi

Veteran Member
Joined
Dec 28, 2009
Location
West Coast Canada
TDI
Tdi asv motor in a mk3 golf, om642 in a wk jeep
Double the stock horse power eh? (Canadian accent)
How does it feel? Happy with those numbers?
I am sure there will be a little tweaking here and there.
Nice build guys..
 

foxracer1

Veteran Member
Joined
Apr 13, 2001
Location
Dayton Ohio
TDI
98 A3 TDI 5spd, 86 w/TDI 02A in prog.
Awesome! I saw this car late 2010 or jan 11 and it was in progress. Looks real nice. Good to see a 1Z makin some ponies!
 
Top