Collection of Dyno Charts and Videos

[Mark@MaloneTuning]

Dyno Charts

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2009 Jetta 2.0L CR TDI 140HP, with no modifications to the engine/drivetrain



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2010 JSW 2.0L CR TDI 140HP Manual

Mods: Stage 2 engine tune and peformance-diesel.com downpipe. off-road only. 4-6 MPG boost!

Dyno plot 1 - without AFE Intake VS. With AFE (ABS and ESP fuses pulled)



Dyno plot 2 - max. 168whp and ~280ft-lb torque - with AFE (smooth numbers) VS. Without and ABS and ESP fuses installed



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2010 Jetta 2.0L 140HP CR TDI DSG

Mods: Stage 2 engine tune, performance-diesel.com downpipe with EGR retained. off-road only. 4-6 MPG boost! HPA DSG tune.

Dyno run #1 - 166.55whp 334.47ft-lb torque


Dyno run #2 - 169.92whp 334.32 ft-lb torque


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2010 Golf 2.0L 140HP CR TDI DSG

Mod: Stage 1.5 engine tune, factory DSG software

Dyno run - 177whp 275.4 ft-lb torque


The client had issues getting good acceleration at low RPM on the dynop, which is why it looks odd in the beginning.

[Mark@MaloneTuning]

Videos

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2011 VW MK6 Golf 2.0 CR TDI 140HP

Mods: Stage 2 engine tune, Performance-diesel.com full exhaust.

Video:


http://www.youtube.com/watch?v=aZ6_4Bts1mI

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2011 VW MK6 Jetta 2.0 CR TDI 140HP

Mods: Stage 2+ engine tune, Rawtek Inc. full exhaust.

Video:

http://youtu.be/BvPxUv2Z7b0

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2009 VW Jetta 2.0L CR TDI 140HP

First 2009 TDI tuned in March 2009, dynoed in April or May 2009.

Mods: Stage 2 tune

Video:

http://www.youtube.com/watch?v=gULtk0b4vRA

Stock results on dyno: 133hp and 225ft-lb torque.
Stage 2 results on same dyno: 168whp and 315ft-lb torque (without line smoothing), 163hp and 295ft-lb (with line smoothing).

The vehicle still has DPF and all emissions systems intact. This explains the complete lack of smoke. That car still runs great since March 2009.

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2010 VW Jetta Sportwagen 2.0L CR TDI 140HP

Video:

http://www.youtube.com/watch?v=xeL_86Dbbx0

Dyno result: 160whp and 270ft-lb torque

Car details and pictures: http://forums.tdiclub.com/showthread.php?t=334431

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2010 VW Jetta 2.0L CR TDI 140HP with DSG

Mods: Stage 2 engine tune, Performance-diesel.com downpipe with egr, full 2.5" performance exhaust and DSG tune. The DPF is deleted - off-road only.

Video:

http://www.youtube.com/watch?v=6ajR6ZTKEnQ

Dyno result: 169.92whp and 334.32ft-lb torque

The smoke level is surprisingly low despite the lack of emissions sytems (off-road only). This is cleaner than almost all older TDIs modified to the same power level, even with their full emissions system intact.

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2010 VW Jetta 2.0L CR TDI 140HP

Mods: Stage 2 engine tune, Performance-diesel.com full exhaust.

For those who are curious about the most possible smoke at WOT without emissions systems (disclaimer: off-road only!), this video taken in hot 100F Texas heat is a good example of it:

Video:

http://www.youtube.com/watch?v=F_hyRwRaPHg
(this video was taken on a private road)

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2009 VW Jetta 2.0L CR TDI 140HP

Mods: Stage 2+ engine tune, Performance-diesel.com full exhaust.

Video:

http://www.youtube.com/watch?v=nHfMhxJqRIo

Dyno result: 195whp and 385wtq uncorrected in Denver, Colorado (high elevation)

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2010 VW MK6 Golf 2.0 CR TDI 140HP

Mods: Malone tune, 2.75" Rawtek Exhaust.

Video:


Video #1:http://www.youtube.com/watch?v=-1YthhIzvSU

Video #2:http://www.youtube.com/watch?v=jHMVCiYPblg

[AO928]

Originally Posted by Mark@MaloneTuning

Dyno plot 2 - max. 168whp and 297ft-lb torque - with AFE (smooth numbers) VS. Without and ABS and ESP fuses installed



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Sorry, but this looks more like an anomaly than actually usable torque.

It's not clear to me how much benefit came from the downpipe vs. the tune? I do like the idea of picking up an addition ~30whp.

[bhutchins]

Mark, with your stage 2 tune on my 2010 with MT and stock exhaust, The MFI Indicated 46 mpg driving from Portland up to Port Angeles, and 47 mpg back down.

[Mark@MaloneTuning]

Originally Posted by AO928

Sorry, but this looks more like an anomaly than actually usable torque.

No need to apologize, you're completely right. I made corrections to the original post to state ~280ft-lb instead of 297ft-lb for that particular dyno.

[Mark@MaloneTuning]

Originally Posted by AO928

It's not clear to me how much benefit came from the downpipe vs. the tune? I do like the idea of picking up an addition ~30whp.

First I should emphasize that modifying emissions equipment is strictly for legal off-road use only. Deleting the DPF, the EGR, the catalytic converter, and in some cases even just changing the muffler is considered illegal on public roads. This type of discussion is discouraged by the tdiclub.com administrators who strongly believe in the Clean Diesel image, which is understandable. Thus, all emissions modifications should be discussed in the context of legal off-road/racing use only.

The exhaust upgrade does not seem to increase the peak HP or TQ potential significantly with the stock turbo. There are a number of benefits, however, described below:

• 4-6 MPG gain reported by most DPF-delete customers. Only a couple people have reported no reduction in fuel consumption so far.
• Significantly improved response during 1st gear engagement. This reduces or eliminates bogging/stalling, particularly with the manual transmission.
• Significantly lower cost alternative to replacing the DPF. One of my customers was quoted $4,000 by a VW dealer to replace his DPF, and his car was never modified. He opted for an aftermarket downpipe for around $750 instead and kept his car for off-road use only. This is an enormous cost difference and it completely eliminates DPF replacement concerns for the life of the vehicle. There are enough stories of Mercedes/Skoda/VW/Audi dealers forcing their customers to pay for their DPF replacements even under warranty with low mileage. DPFs are particularly susceptible to clogging in regions with lower speed limits.
• So far I've seen a ~50C (~122F) reduction in EGT with a full straight-thru exhaust upgrade. This needs to be measured in more cars, but that's the average I'm seeing so far. This means better performance retention during sustained high performance runs. It is noticeable even in more than 10 seconds of WOT. The EGT limiter is hit sooner with a stock exhaust system. Consistently lower EGT during normal driving & racing is also good for turbo and oil life.

[Bob_Fout]

Mark,

I'm interested in the results regarding the AFE CAI. I must not be looking at the charts correctly. What results did you see with it?

Bob

[shortysclimbin]

Mark,

Thanks for transfering over my dyno/ mod list from vortex here to TDIClub.


Originally Posted by AO928
It's not clear to me how much benefit came from the downpipe vs. the tune? I do like the idea of picking up an addition ~30whp.



I would also add that the downpipe has a few other benifits besides what Mark mentioned:

• Lowers underhood temperature by up to 25 Degree F.
• Downpipe is moved farther away from Brake controller reducing brake fluid heat soak and decreased braking abilities.
• Increased room for aftermarket turbos and general maintance.
• Removal of 78 pounds of weight with full systems on most cars!

The exhaust is also quite and does not drone too much in comparison to normal gasser exhaust systems. Many owners have said it is perfect and quite during cruising, and sounds more agressive when on the go pedal.

I'm interested in the results regarding the AFE CAI. I must not be looking at the charts correctly. What results did you see with it?

Bob,

I am actually the one who dynoed the car with and without the AFE intake. I offer it for sale here: http://performance-diesel.com/index....products_id=23 along with other Common Rail products.

[Ryephile]

Thanks Mark and Kyle for collecting data and posting here on TDI Club.

I'm very interested in going for a Stage 2 w/full exhaust [for off-road use only, of course], however it'll be next year; I want to put another 10k miles on the car before kissing the engine warranty goodbye.

Question for Kyle: I want to maximize the fuel economy of the setup and minimize any odors. I understand that keeping the EGR, while not ideal for long-term cylinder-head cleanliness, also improves fuel economy since the engine is getting the opportunity to re-cycle unburnt fuel. Furthermore, in the exhaust path, is it advantageous to run more than 1 [main, H2S, etc] catalytic converters to minimize smelly exhaust?

The last thing I want is to get out of the car [when on the racetrack] and smell like emissions. Would running your downpipe with the high-flow cat and then your straight-back exhaust with just the little muffler be sufficient, or should I keep the downpipe-back stock exhaust?

Thanks,
Ryan

[Bob_Fout]

Originally Posted by shortysclimbin

Bob,

I am actually the one who dynoed the car with and without the AFE intake. I offer it for sale here: http://performance-diesel.com/index....products_id=23 along with other Common Rail products.

Based on those dynos, was there any HP or torque gain? (too small for me to read)

[Ryephile]

Originally Posted by Bob_Fout

Based on those dynos, was there any HP or torque gain? (too small for me to read)

According to that dyno, the AFE was good for 4wHP and 4wLbFt. With only one run of each showing and no datalogging accompanying the dynos, the gains could be more or less than that.

[shortysclimbin]

Ryepile,

Thanks for your interest. Go ahead and send me an email and we can talk about exhausts options for you. I personally like all my downpipes to have a high flow cat as close to the turbo as possible. This reduces nox drastically. The S2O box is designed to catch the rotten egg smelling exhaust when the downpipe fails. I have found that this will NOT remove the diesel smell from your exhaust nor will the muffler although both do help quite the exhaust down a bit and add to egt temps. I will say these cars with full performance exhausts smoke less and smell better than fully oem ALH or PD cars after tuning. This in my eyes is a huge improvement since we now have gained more fuel control and options.

On the AFE I only listed one run. I actually did three runs with it and they where all within the same +-1whp of eachother with the intake on. AFE has it listed at a 7whp gain on a stock car. Other companies claim up to 10whp on a stock car, but I find this highly unlikely. I like the AFE intakes due to their oem design and keeping the air snorkel with rain rejection, and the non oiled filter they use (you can get a higher flow model with an oil filter but I will not sell it!). I have had two customers with MAF issues and APR intakes in the last 6 months... Not good considering the cost of MAFS these days.

[Bob_Fout]

Climbin,

I wish AFE would make this same setup for MK IVs... I have their short-ram setup and another more OEM-like option would be nice.

[Ryephile]

Thanks Kyle for the solid feedback. I'll contact you directly when I'm closer to buying and we'll sort it out. I look forward to seeing how the performance GTI-style exhaust looks!

[shortysclimbin]

Ryepile, - Check out this!
http://youtu.be/aZ6_4Bts1mI

Ask and you shall Receive good sir!