RTDI Part 2

Fix_Until_Broke

Top Post Dawg
Joined
Aug 8, 2004
Location
Menomonee Falls, Wisconsin, USA
TDI
03 Jetta, 03 TT TDI
If you want better control over EGT's, put in bigger nozzles/injectors and dial the fuel delivery back in the tune to an equivalent amount. Basically, anything more than a very light haze of smoke out the back is going to cause broken parts with what you're doing - Keep Air Fuel ratio's in the 18-20:1 range max.

I'd consider this before a water (only water, no meth) injection system and all the extra complexity it adds (and risk if it doesn't work).

Some close up photo's of the piston bowl lips would be interesting to see - Cleaned up with some solvent and paper towel (no media blasting or physical removal). If you can't find any reason for foreign object damage in cylinder 4, maybe a piece of piston broke off?
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
If you want better control over EGT's, put in bigger nozzles/injectors and dial the fuel delivery back in the tune to an equivalent amount. Basically, anything more than a very light haze of smoke out the back is going to cause broken parts with what you're doing - Keep Air Fuel ratio's in the 18-20:1 range max.

I'd consider this before a water (only water, no meth) injection system and all the extra complexity it adds (and risk if it doesn't work).

Some close up photo's of the piston bowl lips would be interesting to see - Cleaned up with some solvent and paper towel (no media blasting or physical removal). If you can't find any reason for foreign object damage in cylinder 4, maybe a piece of piston broke off?
The thing is, is that I've got some pretty big injectors in the car right now. I even went from the +80% Firad nozzles to +120% Firad nozzles on a set of PD100 injectors, which is supposed to be good for 330bhp. My car dynoed at 286AWHP and 404 lb-ft of torque, so I should have plenty as far as fueling goes.
I just think the tune needs to be dialed back for what I'm doing and be less concerned about dyno numbers. Like you mentioned, the car needs to be putting out a low haze and not a plume of smoke everytime the car is coming out of a corner or a gear shift is made.

That's probably a good call on not adding a W/M kit(water mostly kit;) ) Just one more thing to go wrong and add to the complexity of the car.

I'll see if the guy working on my car can get some better/close up pictures of piston 4 to see if there's a chunk of piston missing that went out of the exhaust and into the turbine wheel. It's either that or the possibility that the tip of the injector broke off and caused that damage... I'll see if I can get some better pictures of both piston #4 and the injector from cylinder 4 and post them up.
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
To be honest I don't think that I need to go to a larger size nozzle. The +120% nozzles flow enough for 330bhp and for what I'm looking to do with the car that's more than enough to fuel my car. With the piston failing in cylinder 4 and the turbo getting taken out in the process has me rethinking how much I wanna push this engine setup.

Adam at Pioneering Performance suggested I dial back the fueling after he saw how much soot was built up on the hot side of the turbo and I can understand why after I told him how many hours were on that turbo.

I'd rather start on the lower end of the power spectrum and bring it up little by little until it's making good power, but out of the threshold where it could blow up.
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
With the engine needing to be rebuilt, I decided it would be a good idea to ceramic coat the pistons this time around. My mechanic sent the pistons to Swain Tech Coatings to have them coat the top of the pistons with their Gold Coat and had their PC-9 coating on the skirt.

The pistons look pretty darn good from the pictures my mechanic sent me yesterday when they arrived at his place.





The coating looks a little bit different in the daylight.


Now we're just waiting on them to coat the turbine housing and exhaust manifold and then ship them out when they're done. Unfortunately it might take a bit longer than it normally would with the coronavirus forcing them to adjust their production schedule. Fingers crossed that they can get them coated in the next couple of weeks.:)
 

Kevinski4

Vendor , w/Business number
Joined
Aug 31, 2007
Location
Nebraska
TDI
.
To be honest I don't think that I need to go to a larger size nozzle. The +120% nozzles flow enough for 330bhp and for what I'm looking to do with the car that's more than enough to fuel my car. With the piston failing in cylinder 4 and the turbo getting taken out in the process has me rethinking how much I wanna push this engine setup.

Adam at Pioneering Performance suggested I dial back the fueling after he saw how much soot was built up on the hot side of the turbo and I can understand why after I told him how many hours were on that turbo.

I'd rather start on the lower end of the power spectrum and bring it up little by little until it's making good power, but out of the threshold where it could blow up.

Smoke is power that you can see but not use.
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
Smoke is power that you can see but not use.
If cylinder 4 hadn't failed at the track my plan was to dial back the fueling to clean up the amount of smoke coming out of the exhaust and try and get it closer to a light haze. After this rebuild we'll definitely be dialing the fueling back to increase the longevity of all of the engine parts and turbo.

Then on a side note...my mechanic friend got the turbine housing back from being ceramic coated. It turned out fantastic imo.
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
The last piece of the puzzle arrived late last week and should be on the car already. My friend/mechanic was looking a little bit closer at the bottom end of my old engine and noticed some light blueing on a few of the engine pieces, which he thought could have come from some of those longer right hand turns at Road America, more specifically turns 9&10, otherwise known as the Carousel. https://www.roadamerica.com/post/competitor-map
So to play it safe I order a baffled oil pan from Issam at iABED Industries
Here are a few of the pictures he sent me of it.






That should hold the oil in place.😆
Fingers crossed that my car gets wrapped up in the next few weeks.🤞
 

Poor King

Veteran Member
Joined
May 20, 2020
Location
NY
TDI
'91 Jetta, '91 GTI, '04 Touareg
I was a lurker on here back then and it's great to see your build come thus far 🔥
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
It's been a while since I updated this thread, so I figured I'd let you guys know what's been going on the past few months.

Besides the ceramic coating on the pistons and larger turbine wheel, I wanted another way to help keep the temps in check when out on the track getting pushed to the limit. After doing plenty of research and talking with a few different people, I decided to purchase a Water/Meth kit from Snow Performance/Nitrous Express. Here's the kit I ended up ordering. https://nitrousexpress.com/Stage-2-...-Temp-Nylon-Tubing-Quick-Connect-Fittings.asp

Then when James my mechanic friend was going to fit the PD150 TIP, it didn't clear the new tubular manifold.


Rather than try and modify the PD150 TIP, it just made more sense to order a different TIP and upgrade it at the same time, so I ordered a 3" TIP. https://profidiesel.net/intake-manifolds-tip/80-profidiesel-19tdi-turbo-inlet-pipe-3-76mm-ss.html

When I switched from an Audi style turbo to a BMW(V-band) style turbo I knew that the flange on the downpipe would have to be converted to connect with the turbine outlet. Little did I know at that time that the flange that connects with the turbine outlet on the BMW turbo required a specialty flange that would be somewhat hard to find. Adam at Pioneering Performance was able to help point me in the right direction.
https://www.modosport.eu/shop-1/exhaust-flange-kit-gt-gt2260vk-bmw

This iteration I'm going to run a catch can to keep the intake tract and intercooler setup free of the oil mist that would otherwise make its way into the system. I had ordered one in the past, but didn't get around to installing it, so I sold it. I ordered another one and this time it'll definitely get installed on the car. Here's where I got mine. https://www.idparts.com/mann-provent-200-ccv-filter-3931070550-p-2334.html

Then with any luck the car will be ready for a May 22nd or 23rd track day at Road America. (y) :) :love:
 
Last edited:

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
The catch can, flange and TIP have finally arrived, so everything is hopefully on the home stretch after the downpipe gets modified for the new flange to get welded on. Unfortunately the 90 degree silicone reducing elbow didn't get packed with the 3" TIP, so I had to order one last night. Luckily the place I ordered the 3" to 2.25" (76mm to 57mm) elbow had it in stock and should arrive Wednesday. At least Profidiesel is going to reimburse me for the one I had to order.

Of course who doesn't love pictures. :)







I'm sure they'll be more frequent updates as things get closer to the track day.(y)
 

jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
Interesting oil pan. That may work nicely in a truck that climbs hills often. I had a flat track pan in a V-8 Chevy that was used in the dunes to keep oil near the pick up. I take it that hole in the baffle is for the pump pick up and there is a Vertical baffle to keep oil From rolling to the back? Do you by chance have the part number for that or what it cost?
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
Interesting oil pan. That may work nicely in a truck that climbs hills often. I had a flat track pan in a V-8 Chevy that was used in the dunes to keep oil near the pick up. I take it that hole in the baffle is for the pump pick up and there is a Vertical baffle to keep oil From rolling to the back? Do you by chance have the part number for that or what it cost?
Yep, the hole in the cover is for the oil pickup tube.

There isn't really a need for the pan to be baffled front to back with our transverse layout, but when you're cornering really hard or when it's a long sweeping corner you need baffles to prevent the oil from flowing to the outside portion of the oil pan. So with the baffles placed horizontal in the pan it'll help keep oil by the oil pickup tube when making a hard/extended left hand corner.

The baffled oil pan also holds an extra 0.7L of oil, so that's another nice feature imo.

Here are the 2 places I found that offer the baffled oil pan. I ordered one from both places, since I'm putting one on my other TDI that gets used as a backup track car when this one isn't running for whatever reason. I got lucky with the 2nd one, since it was on sale at ECS Tuning.
https://pgperformance.com/ina-1.8t-baffled-oil-pan.html
https://www.ecstuning.com/b-iabed-industries-parts/aluminum-baffled-oil-pan/462-103-06a~iab/

The pan doesn't come with oil level sensor cover, so make sure to order one of those.
Oil Level Sensor Cover Kit for $17.45
Oil Level Sensor Cover Kit for $27.56

Let me if there's anything else I can help with. :) (y)
 

jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
The transverse mounting didn’t cross my mind. I remember the one I had contained a hinged baffle that allowed oil to flow into the baffled sump but made it go over the top to leave.
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
It took me a little bit longer to post an update than I would have liked, but it's been a bit hectic around here lately.

A big part of it is due to losing my partner in crime, my golden retriever that just turned 8 on May 3rd passed away from an aneurysm last Saturday. He went everywhere with me pretty much, since he was trained as a service dog ever since we got him as a puppy. He kept me going everyday and was the reason I went for walks or explored the area we live in Wisconsin. He was definitely the right dog for where we live, since we're just about completely surrounded by water, so he loved to go swimming anytime the bay wasn't frozen over. 🤣

I know a some of you got to meet him, whether it was at one of my get togethers or at TDIFest 2016, I know he always enjoyed meeting everyone and was always up for going for a ride in my car.

Now for some updates on the car.

I stopped by the buddy that was working on the car back on April 18th to check on the progress of the car. Things were moving forward with getting the flange welded onto the downpipe for the new turbo setup.


The 3" TIP got installed. I wish I had a better picture.


Here are some of the remaining parts that are going to get installed at https://www.kellymoss.com/


Kelly Moss has an absolutely incredible shop and race department. Here are some of cars they had in their shop/race department when we dropped my car off after I picked it up on May 8th from my buddy, since 99% of the TDI related work was done.






They have some monster brakes on their race cars.😲


This was taken a week before Skittles passed away.:cry:


I'll see if I can get them to snap a few pictures as they finalize a few things with the car.
 

Andyinchville1

Veteran Member
Joined
Apr 7, 2016
Location
Virginia
TDI
2003 Jetta TDI wagon, 5 sp, 226K miles
The catch can, flange and TIP have finally arrived, so everything is hopefully on the home stretch after the downpipe gets modified for the new flange to get welded on. Unfortunately the 90 degree silicone reducing elbow didn't get packed with the 3" TIP, so I had to order one last night. Luckily the place I ordered the 3" to 2.25" (76mm to 57mm) elbow had it in stock and should arrive Wednesday. At least Profidiesel is going to reimburse me for the one I had to order.

Of course who doesn't love pictures. :)







I'm sure they'll be more frequent updates as things get closer to the track day.(y)
Hi

That is the TIP i wanted ! ( actually I ordered one , but after a month or so since I still didn't get it i called PayPal and made an inquiry .... rather than shipping it, Profi just refunded my $$ ..... i would rather have had the pipe.

How long did it take to get yours?

Does it seem to help alot ?

I know by upgrading the smic and changing to a brm intake that helped a bunch so i was on a intake / piping upgrade binge.

Thanks

Andrew

PS - you are definitely doing some cool stuff .... looking forward to reading more !
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
Hi

That is the TIP i wanted ! ( actually I ordered one , but after a month or so since I still didn't get it i called PayPal and made an inquiry .... rather than shipping it, Profi just refunded my $$ ..... i would rather have had the pipe.

How long did it take to get yours?

Does it seem to help alot ?

I know by upgrading the smic and changing to a brm intake that helped a bunch so i was on a intake / piping upgrade binge.

Thanks

Andrew

PS - you are definitely doing some cool stuff .... looking forward to reading more !
I believe it took about 2 weeks for the 2nd TIP to get to my buddy that was working on my car. The reason I put 2nd TIP, is that the 1st one got lost in the mail and after 3 weeks I contacted them and asked for a tracking number, which unfortunately they didn't have. At least on the 2nd package they provided me with tracking info, but forgot to include the silicone elbow and CCV elbow. So take that info for what it's worth.

I will say that I plan on picking up another one for my 04 Jetta TDI when I end up installing my Pioneering Performance GTB2260VKLR, since it's a definite upgrade over the factory or even the PD150 TIP.

Hope that helps you out.

I appreciate the compliment Andrew! I should have more to post up in the coming weeks about what's being done with the car, so stay tuned. :)
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
Somewhat of an update. Sadly the transmission had to get pulled again due to the transmission not going into 6th gear and I'm not willing to take a chance that there's something broken off in the transmission that could end up taking out the rest of the gears and the Wavetrac LSD that's in there too.

The trans is getting sent to: http://www.fferacing.com/ in New York. If you're in the area and looking for a shop to work on your car, definitely check them out, since they're able to do a heck of a lot more than repair transmissions.

While it's out of the car, I'm going to have them install a few upgrades to beef up the transmission to hopefully prevent any more issues with the transmission in the future.
To upgrade the USP Motorsports 1-2 and 3-4 Steel Shift forks I'm having Bronze Sliders for O2M & O2Q steel shift forks installed to replace the factory plastic ones that wear out over time.

Then to reinforce the input shaft I'm have a Billet Shaft 02M & 02Q gearbox installed to aid in the strength of the input shaft, so it doesn't cause any problems with the gears being separated under high load.

Another part that I'm having installed is a Spigot bearing for 02M & 02Q gearbox

The final upgrade being done in the transmission is a SQS Racing 5th/6th gear reinforcement arm to hopefully alleviate any future problems with 5th or 6th gear.

Some other upgrades that I considered were the Transitional support 4th gear transmission 02M & 02Q but wasn't too keen on having to create a hole in the transmission housing to install this 4th gear support and then have to worry about adjusting it every so often.

Similar idea with this next 02M & 02Q Gearbox Reinforcement Plate Kit that would require drilling 4 holes in the transmission housing to install it.

These next three upgrades are just cost prohibitive for just a fun track car that doesn't get raced. Granted I'm sure some of them would help improve lap times. 🤣
From SQS Racing, they offer a 3rd-6th syncro gear upgrade that uses your factory 1st and 2nd and they also the same thing, but it would be a Dog Box 02M/02Q (MQ350) SYNCHRO (02Q SYNCHRO BOOST) or 02M/Q (MQ350) DOG-SYNCHRO BOX

Another one of the upgrades is the Bar-Tek DOG Box gearkit for 02M & 02Q gearbox

FFE Racing also offers a 02m 6 speed Dog box kit and I believe they're the only one in the US to do so.

Fingers crossed that there isn't anything major going on in the transmission, so they can fix what's wrong with the trans, install the upgrades, and ship it back to Wisconsin so they can finish up my car before the end of August.
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
In case anyone else has this problem with their O2M, here's what FFE Racing discovered was going on with my transmission.

"I was installing the new parts (shaft insert, 5/6 fork upgrade and shifter arm inserts) and when I installed your shifter mechanism, I noticed the issue. I am going to pull a shift our of another trans and test it in yours. I will report back later today."

Their reply later on that day.
"It in fact was a bent shift mechanism that was causing the issue with 5/6. We had a good condition used one as oem was almost $400.

The brass fork ends were installed. One had to be modified to clear reverse as it was rubbing when all assembled.

The 5/6 upgraded fork arm was installed. This took a good amount of clearance to shift correctly between 5th and 6th,. The detent are was too large and caused it to be very hard to shift between the 2 gears.

The input shaft support was machined down and installed into the shaft. It was then tig welded into place."
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
Sorry for the lack of updates over the past 6 months, but there wasn't too much to post up about until now.

My car is finally back at our shop waiting for some final tweaks to the W/M system, ECU tune, get an alignment done, and fit the new wheels and tires. Everything is going to have to wait until the snow melts here in Wisconsin and we get at least one decent rain shower to clean the salt off of the roads.

If anyone is close to the Green Bay, WI area and would be up for running some logs to help dial in the tune and how the W/M kit works in conjunction with the tune would be amazing!

There really isn't too much as far as pictures go, since not a ton of stuff changed that's new to the car besides the W/M kit, catch can, and there's now a different battery in the car.
Here are the 2 pictures I have.


 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
I know it's been a little while since I posted here, but it's taken me a bit longer than I would have liked to pull the little bit of video footage we got from the micro SD card and uploaded it to my computer. Then of course taking the time to upload it onto YouTube and edit it, so there isn't huge "dead" spots at the beginning and end of the clip.

I finally got it uploaded last weekend and have some time right now, since it's 87° right now with a feel like temp of 90°. Since I no longer sweat after my accident, I have to play it smart and either stay inside or have someone around that can help pour water over my shirt and wrap ice in a Gatorade towel to put around my neck. So today, I'm staying in. 🤣

Onto the track day...things went pretty well for us getting there on time, but we forgot to get a wrist band saying that it was ok for me to ride in the car. So we only got 2 laps in on the 1st session, which is when the video was taken.

We came back in checked everything over and it just needed so more boost juice for the W/M kit.

We were taking it fairly easy during the 2nd session, with some decent pulls here and there, but nothing like when cylinder 4 went on us while we were pushing the car really hard that day.
Unfortunately after we got back from our 2nd session, my driver noticed a tiny bit of coolant coming out the head gasket, along with a tiny amount of oil that could have been coming from the bottom of the catch can. 🤷‍♂️

Fingers crossed that we can get those issues figured out and find a way to prevent them from happening again.

I'm also finally getting my Pioneering Performance GTB2260VKLR installed on my Jetta, so once that's dialed in, I could use it while the RTDI is getting fixed.

Finally onto the pictures and video.










 
Top