Hello!
The whole thing is worth the read, and I’m sorry if it’s not!
I am 19 and I have a 2001 Jetta TDI and was introduced to fuel mileage and range last September, I went to this after daily driving a 500 whp Honda Civic, that I built before I got my license, on E85 and getting 14 mpg on an 11 gallon tank. On a reallly good tank I could get a little over 200 miles on a tank... rarely.... So I love the range of the TDI cars!!!!! I put larger tires on the front to bring back the rpms for cruising 79 mph, the best mileage I’ve gotten with speedo correction due to the tires is about 45ish mpg. Over 600 miles on a tank. It was awesome.
I have been in the diesel industry since I was in elementary school, our neighbors and family friend have a Duramax pulling truck that I always helped work on. I went to my first big pull with them in 2nd grade in Indianapolis and from then on I always wanted to be a part of it. The trucks name is Cummins Killer and is now on the 3rd version since I have been around and competes in the Super Stock Diesel Class and making around 3,000 horsepower with a single 5.250” turbocharger. Through this sport I met so many people and made so many connections and that is how I got my job while I go to school.
During high school I built my 500 whp Honda Civic and bracket drag raced it, my best pass was 11.29@130 mph in the 1/4. I also built a 1986 Mazda RX-7 turbo 4.8 LS swap. I have been fighting little issues here and there. Been to the track a few times with it, my best pass so far was 10.43@132 mph, and there’s lots of room to grow once I get tuning figured out.
I go to school for mechanical engineering at Kettering University in Flint, MI. We go to school for 3 months then engineering related work for 3 months, off and on like that for 4.5 years.
During my work term I work for a diesel performance company, whose name I will leave out for now anyways. We focus on common rail diesel fuel systems and engine calibration for high horsepower diesels. Dragsters, off shore racing boats, trophy trucks, drag racing semis, pulling trucks and every thing in-between.
While at work I have extra money so I’m always looking around on Craigslist, I found an RX-8 that supposedly ran for $700, I was like alright. Even if it doesn’t it’s a good shell for a swap. Of course the rotary was trash. Now I was looking for a good swap for it. I was minutes from just going to buy a turbo ls to slap in it, but I already had done that and it was too easy, mainstream, and basic. Not to discredit it!!!!!!!!! It still take a lot of work and I couldn’t have done it without my dad’s help. But I wanted something unique.
There just so happened to be a 2010 2.0 TDI engine from a Jetta with 140,000 miles on it for sale with everything for $600. I was sold. It was definitely different. I figured I work for a diesel company, I should have a performance diesel car.
I have set lofty goals, it used to be 250-300 horsepower. But my goal is now 300-500 horsepower.
Engine build so far.....
Block Line honed
Bores honed
Rings Gapped.. top 0.024” and second 0.035” better a little big than a little tight.
ARP main studs from Nissan L20 engine
ARP head studs from a 6.7l 24 valve Cummins with the top of the stud shaved down around 0.5” to miss the cams, I used the factory washers, not the ARP washers
Integrated Engineering Tuscan Rods with ARP hardware
Stock cams
Stock springs
Stock head
Engine management......
After long debate with myself and searching. It seemed very difficult to tune a stock TDI ecu yourself. I want to do a full engine dyno tune at work... after some digging I think I can get my hands on a Bosch MS 15 Sport Stand-alone ECU to get around the tuning struggles. This led to other issues though, the stock injectors are Piezo.... ugh.... I now needed to find solenoid injectors to take the place of them. As it so turns out, we have been playing with the new Duramax L5P injectors a bit. And I got lucky enough that it was able to fit right in the VW head with a small amount of milling! I was ecstatic to see this work out.
Fuel System......
Injectors: Modified L5P Duramax injectors
High Pressure Fuel Pump: 5.9l Cummins CP3 pump fits with a lot of grinding!!! I was so stoked to find this out because that is a pump we know well and I didn’t want to have to buy a kit and a funky smaller CP3.
Turbos....
I’m going to build my own compound turbo kit, most likely going with a slightly bigger than stock size high pressure turbo, the buy a 64xx don’t remember exactly what.. from a coworker as a low pressure turbo to feed the high pressure turbo. Might be a touch big, but we will see.
Transmission.....
I plan to attempt to build my own adapter plate to mount it up to a T56 transmission. I might end up just buying one though if it works out that way.
I still have a lot to work out and questions to ask and get answered. To name a few...
Is there a place to post build threads on here????
How is that alternator controlled? Can it be made 1 wire or should I just send a PWM signal to it related to voltage or RPM?
How is the pressed on reluctor wheel thingy supposed to go on? I got a new one with my rear main seal and I’m unsure of the orientation of it? There’s a chance I will be getting rid of it and going with a 60 minus 2 tone wheel for the standalone. But I would still like to know.
Is there any kind of Cam position sensor on it?
Does the engine sit at any kind of an angle when it’s in the factory position in a Jetta?
Does anyone have some oil squirters? I’m an idiot and broke a couple when pitting pistons in, the rods hit them......
I hope that wasn’t too much for you guys.
If you read the whole thing, thank you so much!!!
Make Diesel Great Again!!!!