99.5 2.0 Golf Build

bgsnyder

Veteran Member
Joined
Jan 13, 2008
Location
Cedar Rapids, IA
TDI
99.5 Golf & 2005 Passat
81.5mm BHW pistons, Rosten Rods, Ported head, GTB2260VKLR turbo. It already has the 337 rims and 20th anniversary springs.
 
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bgsnyder

Veteran Member
Joined
Jan 13, 2008
Location
Cedar Rapids, IA
TDI
99.5 Golf & 2005 Passat
I'm hoping for 300 HP. I don't know if I'll get it but somewhere around there is what I'm thinking. As long as I'm faster than my buddies supercharged Caviler I'll be happy. He runs low 14 quarter miles.
 

bgsnyder

Veteran Member
Joined
Jan 13, 2008
Location
Cedar Rapids, IA
TDI
99.5 Golf & 2005 Passat
Getting there, more progress last night. Got the exhaust back on, got everything in time and tensioned, Turbo and intake manifold on, Fluidampr installed. Turbo oil lines done.






 

bgsnyder

Veteran Member
Joined
Jan 13, 2008
Location
Cedar Rapids, IA
TDI
99.5 Golf & 2005 Passat
I'm hoping for 250-280 HP. Still waiting on Fuel Injectors. Hopefully they will be showing up today. The turbo to existing intercooler piping didn't line up right, so i'll have to figure that out. There's snow on the ground now, so breaking it in is going to be interesting.
 

bgsnyder

Veteran Member
Joined
Jan 13, 2008
Location
Cedar Rapids, IA
TDI
99.5 Golf & 2005 Passat
Got it running but I'm not getting any boost. I have a 17566/P1158 - Manifold Pressure Sensor (G71): Implausible Signal Error. Any ideas?
 

JeffDes4

Veteran Member
Joined
Oct 31, 2013
Location
Saginaw
TDI
Jetta
Any of these?
Wiring and/or Connections from/to Manifold/Barometric Pressure Sensor (G71)/(F96) faulty
Leak in Air Intake and/or Exhaust
Manifold/Barometric Pressure Sensor (G71)/(F96) faulty
Engine Control Module faulty
 

bgsnyder

Veteran Member
Joined
Jan 13, 2008
Location
Cedar Rapids, IA
TDI
99.5 Golf & 2005 Passat
Could I get this error if the VNT actuator rod was way out of spec? I haven't adjusted it yet, and I know I still have to. It's a brand new 4 bar map sensor so I'm hoping it's not that.
 

bgsnyder

Veteran Member
Joined
Jan 13, 2008
Location
Cedar Rapids, IA
TDI
99.5 Golf & 2005 Passat
The MAP sensor, group 11, with the car off is 980 mbar, which makes sense. With the car running it goes to 3962.4 mbar. When you cycle the n75 valve it doesn't change. Also, the exhaust sound never sounds like the vanes are closed enough. I never get the hissing from the turbo. I adjusted the vnt rod shorter, but it seems to stop in the same spot, and I don't believe there is a stop screw.
 

bgsnyder

Veteran Member
Joined
Jan 13, 2008
Location
Cedar Rapids, IA
TDI
99.5 Golf & 2005 Passat
Intercooler pipe popped off while adjusting the turbo actuator so I built this to pressure test everything and make sure there are no boost leaks.
 

Windex

Top Post Dawg
Joined
Apr 1, 2006
Location
Cambridge
TDI
05 B5V 01E FRF
Did you figure out the MAP code - I was thinking that your tune and the 4bar MAP were not in sync.
 

bgsnyder

Veteran Member
Joined
Jan 13, 2008
Location
Cedar Rapids, IA
TDI
99.5 Golf & 2005 Passat
Yeah it was the tune, now I'm trying to get the actuator adjusted. Still not getting boost, but i think it's going in to limp mode because the actuator is still off a little. Hopefully I can get it figured out tomorrow.
 

Windex

Top Post Dawg
Joined
Apr 1, 2006
Location
Cambridge
TDI
05 B5V 01E FRF
Have you tested it with a vac pump? most start to move at 4" vac and are fully against the stop at 18"
 

bgsnyder

Veteran Member
Joined
Jan 13, 2008
Location
Cedar Rapids, IA
TDI
99.5 Golf & 2005 Passat
I got the actuator moving at 4" and stopping at 18". I logged group 11 and here is what I'm getting. This is first and second gear I think. I am only getting about 5 psi on the boost gauge. At idle specified is 995.4 actual MAP is 1042.8.

 
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bgsnyder

Veteran Member
Joined
Jan 13, 2008
Location
Cedar Rapids, IA
TDI
99.5 Golf & 2005 Passat
Getting closer. I unplugged the MAF sensor and now I'm actually getting boost. I'm adjusting the arm length shorter, but I don't want to go too far. This is how the curve is looking. I'm only getting about 25 PSI.

 

duwem

Veteran Member
Joined
Apr 11, 2012
Location
Wi
TDI
2002 Golf GLS TDI 5 Speed
Sweet! I would have gone with ceramic coat vs header wrap, but otherwise looks awesome.
 
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