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Other TDI/Diesel Picture Gallery Do you have a TDI or Diesel not listed above? If so write a message here describing it and insert a picture if you have one. If you don't have one on the computer, email me and I'll give you my address and I'll scan it for you. If you need web space for it, email me as well. Please make a short yet descriptive title for your vehicle.

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Old October 26th, 2016, 02:25   #76
xjay1337
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CT-14196-(ZF-4963-30979-1-002)-2 by Fat Bear Photography, on Flickr

CT-14062-(ZF-4963-30979-1-001)-1 by Fat Bear Photography, on Flickr



Car behaved itself well.
PS4's were brilliant on the front, stuck well but did feel a bit roly poly.
AD08R were good on the back, back end was dead planted. I think with 245/40 AD08R on the front it will really help.
Currently we are 235/40 F and 245/40 R.

When I ran 245/40 Direzza 03g it was so planted, but they are too expensive for daily use so while I only have 1 set of tyres I think the AD08Rs are a great compromise.

I've moaned about it elsewhere but oil temps are driving me mental.
I am booked in early November with Alex for oil cooler.

Once that's in I should be fine and able to keep on it a lot more.

I am mid house move at the moment so not sure when the Go-Pro footage will be uploaded. Not much to see anyway.
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Old October 26th, 2016, 18:05   #77
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Great pictures! I'm looking forward to seeing the video.

Have you thought about getting a set of track only wheels and tires to put on either at the track or at home before heading to the track?
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Old November 2nd, 2016, 04:38   #78
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Here's the footage.

https://www.youtube.com/watch?v=7F16tUuTwuY

Trackday wheels, yes now that I have some extra space and a garage I can keep them.

Winter build plans soon to be underway.
I managed to source a complete head for very reasonable money.

IMG-20161101-WA0002 by Fat Bear Photography, on Flickr

IMG-20161101-WA0004 by Fat Bear Photography, on Flickr

Inlet valves are very clean especially compared to some TFSI's I've seen.

Going to be an expensive few months...
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Old November 2nd, 2016, 20:41   #79
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Looks like a good time out on the track.

Was the car getting that hot that you had slow down and move over to cool the car off?

Those Porsche drivers can be real pricks
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Old November 2nd, 2016, 23:27   #80
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Yes, unfortunately after 2 or so laps oil temps went from 95-100 to over 120 and 120 is the max im prepared to run to, my oil (millers nanodrive 10w50) is a competition oil supposedly good for 150 peak sustained but i dont want to risk it.
Oil cooler goes on in a week so that should help
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Old November 11th, 2016, 04:34   #81
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Oil cooler update.

Due to track related oil temperature problems I wanted a solution. I had an idea and spoke with Alex @ AKS and we decided to try some stuff.

Darkside Developments sell a kit with a Mocal thermostatic plate but the oil cooler provided was a cheap Chinese one, so that was sent back and Alex sourced a Mocal 13 row cooler and kept the Thermostatic plate.

20161110_104249 by Fat Bear Photography, on Flickr

I won't bore everyone with the fitting details but it wasn't exactly "bolt on".

We had to retain OEM oil cooler (OEM is a heat exchanger oil is circulated with coolant) however we had to modify the OEM oil cooler and remove the water feed.

20161110_131937 by Fat Bear Photography, on Flickr

Alex welding the brackets to give the right level of support.

20161110_151626 by Fat Bear Photography, on Flickr

Final fitted position.

20161110_185731 by Fat Bear Photography, on Flickr

We started at 10am and I left the workshop around 8pm. We weren't working on it flat out all day though, but it was a bit fiddly.

We did also fit H&R 28/24 front and rear roll bars. This has really stiffened it up in the corners. Lovely.

Oil temps are much better now. Cruising they get to around 80 and stay there due to thermostatic plate. Even with several hard and long acceleration pulls it barely reached 90 so that's much better. Very happy.
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Old November 14th, 2016, 04:09   #82
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Met up with Bobby on Saturday at Surrey Rolling Road
Had a good afternoon chatting to people.

Due to some of the figures coming out of Europe (claiming 270bhp + on stock cp4 pump) we decided to run a test on my car.

We ran a new map, with a dummy EGT sensor (so no EGT protection)
requested lambda 0.9 (another 5-10% more fuel than before)
(normal tune lambda is 1.1-1.2)

20161112_121707 by Fat Bear Photography, on Flickr

Even with the extra boost we were just getting extra smoke. Logs show lambda didn't get below 1.08.

You can see the graph before and after here. The pink (better curves) are the new v25 map and the blue ones were the old v24 map.

20161112_122514 by Fat Bear Photography, on Flickr

You can see while we have dumped loads more fuel in, we are now up to over 430 lb ft of torque however power is exactly the same as before, albeit it holds at the top end now (due to EGT protection effectively not working).

Flat power curve is all well and good but further proves no more airflow available.
We are slowly ruling out any mechanical restrictions to downpipe or intake however this further points to prove that airflow through CR170 head is poor.

We thought the OEM lambda probe was faulty or defective as we could not believe the logs so we ran an independant Lambda probe

20161112_174952 by Fat Bear Photography, on Flickr

20161112_175001 by Fat Bear Photography, on Flickr

IMG-20161112-WA0008 by Fat Bear Photography, on Flickr

Turns out the oem lambda was within range and not telling us lies. We are 100% out of air.



On this particular tune due to excess fuel we were seeing a peak of 2.7bar despite request 2.4

After testing we put v24 tune back on as this tune is not safe for daily use.
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Old November 14th, 2016, 22:50   #83
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Now it's time to port the sh|t out of that new head you got and see if you improve
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Old January 16th, 2017, 12:34   #84
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Gave the car it's yearly wash and decontamination.
IMG_4136-3 by Fat Bear Photography, on Flickr
Just a gentle polish, combination of Scholl S20 Black and Megs 205 on a mediumy pad (Green Hexlogic if you're interested).
IMG_4142-6 by Fat Bear Photography, on Flickr
Coated with Gtechniq Crystal Serum light which was a breeze to be honest.
IMG_4153-15 by Fat Bear Photography, on Flickr

Thanks to Elite Car Care for the use of the unit :-)

I have a trackday. See how we stand with the oil cooler and suspension tweaks. (the H&R Rollbars and also fitted an UltraRacing underbody brace.)

After that I am collecting a Blue Needle cluster. (mine has Red needles. Blue came on some R-Line models)

And also Friday, getting a braided clutch line done at AKS as my OEM pipe burst leaving me broken down.
Annoyingly when we did the oil cooler we were going to do one but ran out of time.

I have sourced some additional parts as well with the help of Bobby, to help with power.
We have lots of special parts to go on. We will begin the rebuild soon.
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Old January 26th, 2017, 05:39   #85
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Did the trackday

https://youtu.be/W61NeEho4Mg






Fitted the braided clutch line.



And new cluster fitted.

Original



New (Mk6 GTD cluster, with Blue needles, blue SMD on circuit board).





Engine rebuild will start soon :-)
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Old January 26th, 2017, 09:47   #86
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Engine build soon?

Can't wait to see the details on that
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Old January 26th, 2017, 19:38   #87
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Looks like you were having a fun time out on the track, maybe too much fun in that one corner you over shot.
What's that metallic clank when you're cornering?

What rear wing is that on the car? I've been considering putting one on my Golf, but not sure what would fit...

I really like the look of the new cluster.
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Old January 27th, 2017, 01:08   #88
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Quote:
Originally Posted by ATR View Post
Engine build soon?

Can't wait to see the details on that
We have ported head, new turbo and many other components.

We are aiming for mid to late feb turnaround, there are some annoying bits to sort out with Pipework but we will get there in the end.

Quote:
Originally Posted by 3L3M3NT View Post
Looks like you were having a fun time out on the track, maybe too much fun in that one corner you over shot.
What's that metallic clank when you're cornering?
What rear wing is that on the car? I've been considering putting one on my Golf, but not sure what would fit...
I really like the look of the new cluster.
Haha, yes, the video was from my first session and my first time at this circuit. So totally newbie to it. As the day went on I found some better lines and could go faster.

The metallic clunk is some alloy pipes I had behind the seats. After the track day I went to AKS Tuning as Alex is going to fabricate me up a new EGR / ASV delete pipe and I had a couple of different sizes of pipe so we could try some different things.

The wing is from a racing team in the UK who compete in the VW Racing Cup.

Cheers
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Old January 27th, 2017, 20:59   #89
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Don't forget some pictures of the rebuild
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Old February 3rd, 2017, 14:36   #90
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Two years ago I ran into the same issues. I actually sold my performance cams, ported, head, dual valve springs, and custom valves last year to a guy in the usa.

Some helpful info maybe:

1) the v6 3.0l TDI CR motors have valves that are about 3mm larger in diameter than oem and same dimensions. they are also sodium filled! I'd suggest running those and just changing the slope angle and valve seat angles on them to fit your needs.

2) the oem intake valve ports split the air and have a very very aggressive reflow swirl built into one of the intakes for low RPM swirl and emissions. Removal of that will drastically help higher RPM but may mean more emissions on lower RPMs. Since you have a good tuner who isn't minding to tinker with new things, (unlike our USA tuners). I'd suggest you keep the intake flapper valves and use the controls to flow more at lower RPM through the single swirl valves that are like the MK4 VE heads. Those intake tracks I'd suggest to only clean them up and worry about the valve seat angles at first! By doing this you will drive a large volume of air at lower rpm to the swirl ports and you can take the old swirl ports and create them into straight feed valves like gas cars for higher RPM. Watch your flow ratios though to make sure you don't kill the swirl and 80% intake to exhaust flow ratio.

3) The cams which have been tested as drop in were used on stock heads. I suspect the flow ports in the head design are actually the limiting factors. Cams on top of a good port job may drastically increase your power potential at higher rpm if you can keep your fuel pressures up in the rail.

4) with the CP3 we were still seeing some fuel rail pressure drops. This was resolved by replacing the stock engine bay electric fuel pump with a heavy duty diesel one that the flows 3 times more pressure.

5) watch that transmission 4/5 gear spread. at the ~390ftlb these manuals have a tendency to walk the gears apart on the 02S transmissions. you might want to get that brace in there if it isn't there already.
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