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VW MKIV-A4 TDIs (VE and PD) This is a general discussion about A4/MkIV Jetta (99.5-~2005), Golf(99.5-2006), and New Beetle(98-2006). Both VE and PD engines are covered here.

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Old February 15th, 2019, 17:36   #1
BakoTDI
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Default Nozzle and clutch upgrade: need guidance

So I need a new clutch for my ALH Mk4 Jetta. I have the stock turbo but I need to replace my nozzles. Iím in desperate need of guidance on this.
I canít upgrade turno at this time so what options might I have in order to be able to support a possible turno upgrade in the future?

Been considering these:
SBC stage 2 endurance or daily
DLC 764 nozzles

Kerma offers different calibration stages for the nozzles as well. Thatís something else Iíd like some assistance on.

With this possible setup, will I need a tune? If so, I need some light shed on me on this issue.

Anyway! Thanks and I appreciate your input.


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99 Canyon Red Pearl MK4 Jetta, 5-spd, South Bend clutch Stage 2 Endurance, Firad P502 nozzles, EGR delete, Stage 3 Malone Tune coming up...I'll eventually get to a bigger turbo
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Old February 15th, 2019, 18:36   #2
Nero Morg
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From personal experience, you can rock DLC520'S with a stock turbo, but as soon as you do a tune, you'll definitely need to do the clutch. Good thing you're in the market for one already!

Since you have to stock 10mm pump, you could probably get away with running the DLC764s without upgrading the turbo.

I would definitely advise getting a tune. You'd probably sit at about a stage 2.

As for the clutch, I've heard the stage 2 dailys have oem similar clutch effort. I can personally testify the stage 3 is at least double the effort. Almost feels like mechanical linkage clutch.
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Old February 15th, 2019, 19:00   #3
BakoTDI
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Awesome! Will using Daily stage 2 be ok with an upgraded turbo later on? Or should I go with the Endurance to be set in case I do go to VNT17 or Warner S7?

What is the difference between the Kerma tuning and the Malone tuning?

I get that tune stage 2 is good for my stock. What about staging on the nozzle calibration?


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99 Canyon Red Pearl MK4 Jetta, 5-spd, South Bend clutch Stage 2 Endurance, Firad P502 nozzles, EGR delete, Stage 3 Malone Tune coming up...I'll eventually get to a bigger turbo
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Old February 15th, 2019, 19:15   #4
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From what I've read, stage 1 is good for stock, stage 2 is better with nozzles. As for who you use as a tuner, it all comes down to preference. I used malone, but that's because the dealer I used locally is an authorized vendor of malone.

As for the stage 2 clutch, I've heard it'll handle a 17 turbo just fine. Only reason I went with stage 3 is because my stock was slipping too badly and it's all they had in stock at the same local vendor.
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Malone Stage 2 w/ South Bend stage 3 endurance
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Old February 15th, 2019, 19:40   #5
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Bako here are a couple very informative links:
http://dbwllc.net/
https://malonetuning.com/ecu-tuning/...gen/tdi/ve-tdi
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Old February 15th, 2019, 19:57   #6
Rrusse11
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"different calibration stages for the nozzles as well. Thatís something else Iíd like some assistance on."

In a word, don't. Set 'em to stock 220/300 bar. DLC764s are big without a major turbo upgrade.
Idparts has Firad 502s (.216) which are plenty big enough. That and a VNT17 down the road make a great snappy
daily driver, that should deliver good FE.

The Southbend stage 2 Endurance is a great clutch in my experience.
A touch more pedal effort than stock, but after 10 minutes of driving
you'll never notice it, and it'll take any tune upgrade you're ever likely to get.

"Stages" of tune is all a bit relative. Depends on what you're after.

My $.02 FWIW.
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Old February 15th, 2019, 20:52   #7
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I have the "Sachs Power Clutch for TDI with G60/VR6 Flywheel" and I love it. Very little effort to press down the clutch pedal. No slippage yet with my stage 4 Malone tune.
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Old February 15th, 2019, 21:10   #8
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Quote:
Originally Posted by Rrusse11 View Post
Depends on what you're after.

Iím looking for a reasonable setup with my stock turbo that will also work with an upgraded turbo down the road.

Feedback so far is that SBC Stage 2 is a good option with a stage 2 tune (a must) and stock calibration (stage 1) on nozzles is good enough for the DLC764s, WITH my stock turbo.

Now this: will the Daily vs. the Endurance make a big difference?








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Old February 15th, 2019, 22:58   #9
Nero Morg
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I think the only difference between the two is you get a few extra ponies out of the one clutch, and the $$$.


Going with the nozzles, clutch, and tune, you are definitely opening the gateway to better mods. Next step after that would be bigger turbo, bigger exhaust, ported intake, EGR shennanigans...



You can always email Malone or call Kerma and chat at them about what you wish to accomplish, and they'll give you suggestions for it. I personally would go with the injectors you are already banking on getting, clutch, tune, then start saving for the turbo. Without the tune you may smoke quite a bit, unless you severely turn down the injection quantity.
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ESP retrofit, MFSW retrofit
Malone Stage 2 w/ South Bend stage 3 endurance
Midwest Light Creation's HID headlights
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Old February 16th, 2019, 04:07   #10
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How many miles on your '99? Original clutch and flywheel? If it's original and not too worn it will be fine with nozzles and a tune. The LUK kits on '99.5 cars was stronger than kits on later cars.

My advice would be to get some .205 nozzles (like the Firads we sell, shameless plug) and have a local Bosch shop set them up. Much less expensive. And send your ECU to Rocketchip to get it socketed (need to do that on '99.5s) and a Stage 3 tune. That's a strong setup. I ran that in my first '99.5 Golf on track days with the OE clutch and it worked great.
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Old February 16th, 2019, 06:07   #11
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I have a Stage 2 endurance in my 01 and the pedal feel was lighter than stock and my 2000 with a stock and is also heavier than the endurance in the 01. It handles every bit of torque my 01 makes with all the goodies on it.

I've heard great things from the G60 setup but have never ran one.

South bend has impressive customer service and completely stands behind their products. I had an issue bedding or seating my clutch and within an hour they had replied, apparently I wasn't driving it hard enough...after that it's been Rock solid for almost 50k miles.

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Old February 16th, 2019, 06:53   #12
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Quote:
Originally Posted by IndigoBlueWagon View Post
How many miles on your '99? Original clutch and flywheel? If it's original and not too worn it will be fine with nozzles and a tune.

have a local Bosch shop set them up. Much less expensive. And send your ECU to Rocketchip to get it socketed (need to do that on '99.5s) and a Stage 3 tune. That's a strong setup.

I got about 280K, not original clutch and flywheel but it was replaced along with transmission about 14 years ago. I might go with the local shop idea. Not sure I can deal with the downtime, since it's my daily driver. I guess I still have to send it out for tuning anyway. Might have to consider this too.
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Old February 16th, 2019, 18:57   #13
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Bako,
Buy a set of injectors and an ECU. No downtime, other than installation when they return. Do have the immobiliser deleted on
the ECU, just make sure the numbers match. Plug and play, should be less than $200 for both. A couple hours to install if you're at all handy.
Depends on what your downtime is worth.
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Old February 16th, 2019, 18:59   #14
BakoTDI
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Default Nozzle and clutch upgrade: need guidance

Quote:
Originally Posted by Rrusse11 View Post
Buy a set of injectors and an ECU.

Woah! Ok, you threw me a curve ball! Buy an ECU? Have not heard of this route! Can you please explain? Or DM me, that works too



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Old February 16th, 2019, 19:06   #15
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Quote:
Originally Posted by BakoTDI View Post
Woah! Ok, you threw me a curve ball! Buy an ECU? Have not heard of this route! Can you please explain? Or DM me, that works too



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I think it's so you can use a 2000+ ecu with your existing harness and be able to flash new tunes via the OBD2 port. Your car you currently can't.


Edit: After some quick searching, 98 (New beetle TDI's) and 99 all ALH's had a 80 pin ECU, 2000-2003 had the 121 pin ECU's, so it's not just plug n play. Dern.
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2003 Jetta Wagon silver- DLC520 VNT15 11MM pump 5 speed
ESP retrofit, MFSW retrofit
Malone Stage 2 w/ South Bend stage 3 endurance
Midwest Light Creation's HID headlights

Last edited by Nero Morg; February 16th, 2019 at 19:09.
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