04 Jetta TDI Upgrades? (BEW)

__.Nico

Member
Joined
Apr 21, 2024
Location
Bakersfield
TDI
2000 Jetta
I recently just bought an 04 Jetta TDI manual. Loving the car and the gas mileage I’m getting but I’m wondering what are some upgrades I can do to get some more power out of it? I’m not looking for crazy power or anything just a little more kick. Everything on the car is completely stock.
 

JDSwan87

Black Swamp Thing
Joined
Feb 9, 2014
Location
Michigan near Toledo
TDI
2001 Jetta TDI, 5 speed Lagoon Blue Metallic(sold); 2005 Jetta TDI Wagon auto
First would be preventative maintenance
Timing belt and water pump service
Oil change
All filters changed
Gearbox fluid drain and refill
Make sure the in tank lift pump is working (listen for the buzz when you first turn the key to the run position)
Front and rear pads and rotors all good?

Once all that is done, you have a good baseline for a mild tune. Be warned, your clutch will need replaced next
 

MORTAMIR

Veteran Member
Joined
Jun 2, 2020
Location
Washington
TDI
MKIV GOLF 05 BEW, 05 Jetta Wagon(not rolling),2000 Golf, DURAMAX LBZ, X5 35D
First would be preventative maintenance
Timing belt and water pump service
Oil change
All filters changed
Gearbox fluid drain and refill
Make sure the in tank lift pump is working (listen for the buzz when you first turn the key to the run position)
Front and rear pads and rotors all good?

Once all that is done, you have a good baseline for a mild tune. Be warned, your clutch will need replaced next
Fuel filter.
 

CanadianALH

Veteran Member
Joined
Aug 21, 2023
Location
Canada
TDI
2002 Jetta 5spd 2006 Jetta DSG (wifes)
First would be preventative maintenance
Timing belt and water pump service
Oil change
All filters changed
Gearbox fluid drain and refill
Make sure the in tank lift pump is working (listen for the buzz when you first turn the key to the run position)
Front and rear pads and rotors all good?

Once all that is done, you have a good baseline for a mild tune. Be warned, your clutch will need replaced next
Yes a good ole stage 0. Then a burpod tune! I would also have a look at your cam for wear as it’s a PD
 

__.Nico

Member
Joined
Apr 21, 2024
Location
Bakersfield
TDI
2000 Jetta
First would be preventative maintenance
Timing belt and water pump service
Oil change
All filters changed
Gearbox fluid drain and refill
Make sure the in tank lift pump is working (listen for the buzz when you first turn the key to the run position)
Front and rear pads and rotors all good?

Once all that is done, you have a good baseline for a mild tune. Be warned, your clutch will need replaced next
All that is taken care of already which is why I’m asking for mods haven’t touched the clutch yet because it’s still feel great
 

KrashDH

Top Post Dawg
Joined
Dec 22, 2013
Location
Washington
TDI
2002 Golf
Kind of want to get some use out of the clutch before replacing as it still feels great. Im not looking for crazy power just a little more juice
I mean up to you of course. I'm just of the mentality of supporting mods before power. What happens if you destroy the clutch and it damages other, more expensive transmission parts?
 

__.Nico

Member
Joined
Apr 21, 2024
Location
Bakersfield
TDI
2000 Jetta
I mean up to you of course. I'm just of the mentality of supporting mods before power. What happens if you destroy the clutch and it damages other, more expensive transmission parts?
100% makes sense, I’m not very knowledgeable on how good or bad these clutches are but that’s why I just want a little more power nothing crazy. But I mean if even a little more power puts stress on the clutch like that then yeah I’d definitely upgrade it first
 

mjydrafter

Veteran Member
Joined
Jul 12, 2015
Location
dsm, ia
TDI
2004 Jetta Wagon
I'm running a stage 1 tune with a stock clutch. Seems fine to me, but I'm an old guy. I just drive it and tow my trailer around. :)
 

mittzlepick

Veteran Member
Joined
Mar 18, 2001
Location
union maine
TDI
2004 jetta wagon (365k)2001 wagon tire burner 6spd 2003 wagon(417k)
Finished my clutch with a stage 2 in a week had 110k. They generally slip in higher gear especilly if you forget to downshift. Nothing is a better motivator than a broken car to get it racing again
 

gforce1108

Top Post Dawg
Joined
Aug 2, 2006
Location
Newburgh, NY
TDI
04 Jetta GLS BEW, 14 Audi A7 V6 TDI, 13 Porsche Cayenne V6 TDI
I started with a rocketchip "1.5" (the real rocketchip, not the scam company advertising online now). That was the highest he would go with a stock turbo. Real nice bump - the way the car should have come from the factory. Once you go farther - it will snowball.

Next is bigger turbo and of course a matching tune. IATs will shoot up and your clutch WILL slip (stock lasted a little while). FMIC to address IATs. Eventually your EGR cooler tubes will fail. Install a better flowing intake manifold to remove the cooler. BRM flows best, "euro" PD150 style second best (anything is better than the BEW manifold). Then you'll find you have no traction with a 1 wheel drive fwd car so better tires and suspension and a limited slip. Stock fuel system will handle 150-180hp-ish (I still have a slight haze of smoke at 24PSI on WOT).

After all that, buy a 3.0 V6 TDI that comes stock with 240hp and 420tq and AWD but still gets upper 30MPG :) (then tune it too!!!)
 

__.Nico

Member
Joined
Apr 21, 2024
Location
Bakersfield
TDI
2000 Jetta
I'm running a stage 1 tune with a stock clutch. Seems fine to me, but I'm an old guy. I just drive it and tow my trailer around. :)
That’ll probably be good enough for me too then lol. Just want a little more power. I’m still young but as I’m getting older trying to get the max amount of power out of everything I drive isnt as appealing as it once was haha. Bought this car cuz of the MPG it’s gets but it would be nice if passing people was a little easier sometimes.
 

__.Nico

Member
Joined
Apr 21, 2024
Location
Bakersfield
TDI
2000 Jetta
I started with a rocketchip "1.5" (the real rocketchip, not the scam company advertising online now). That was the highest he would go with a stock turbo. Real nice bump - the way the car should have come from the factory. Once you go farther - it will snowball.

Next is bigger turbo and of course a matching tune. IATs will shoot up and your clutch WILL slip (stock lasted a little while). FMIC to address IATs. Eventually your EGR cooler tubes will fail. Install a better flowing intake manifold to remove the cooler. BRM flows best, "euro" PD150 style second best (anything is better than the BEW manifold). Then you'll find you have no traction with a 1 wheel drive fwd car so better tires and suspension and a limited slip. Stock fuel system will handle 150-180hp-ish (I still have a slight haze of smoke at 24PSI on WOT).

After all that, buy a 3.0 V6 TDI that comes stock with 240hp and 420tq and AWD but still gets upper 30MPG :) (then tune it too!!!)
V6 TDI with 240ho and 420tq? Which one is that sheesh. relatively new to TDi’s well diesels in general lol. My main concern rn is just mpg but I just want a little more push when trying to pass people. But maybe down the road that v6 might be something fun to look at
 

pedroYUL

Top Post Dawg
Joined
Sep 8, 2011
Location
MI, USA
TDI
2015 Passat CVCA; 2015 GSW CRUA; 2012 wagon CJAA; 2004 wagon BEW(brother)
Any tunes you would recommend? I’ve been looking at Malone but I keep hearing about kerma. Not many videos out there on them though
Not sure if member @burpod is already dipping his toe into PD tuning, but maybe ask him. Otherwise, I only have experience with Green Diesel Engineering, which I believe are still around, I was fairly satisfied with that tune...I checked and they stopped tuning VWs.
 
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boertje

Veteran Member
Joined
May 24, 2002
Location
Coeur d'Alene, ID
TDI
'01, '01, '03, ‘06 NB - TDIs all.
Any tunes you would recommend? I’ve been looking at Malone but I keep hearing about kerma. Not many videos out there on them though
No! Contact @burpod He did my 06 bew dsg bug. It had a malone stage 1 tune and while it had some getup and go, logging revealed excess boost while cruising at 70, over advance on timing and long long crank times on startup when warm along with crap economy. 42 was about the best i could hope for but 40 was the norm.

Now with the @burpod tuning, i have hit 46 and now average 44 so a 10% increase in econ. It now starts as soon as you hit the key when warmed up and the boost and timing have been tamed.
 

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
Not yet, haven't had the time.. hope to one of these days
 

gforce1108

Top Post Dawg
Joined
Aug 2, 2006
Location
Newburgh, NY
TDI
04 Jetta GLS BEW, 14 Audi A7 V6 TDI, 13 Porsche Cayenne V6 TDI
V6 TDI with 240ho and 420tq? Which one is that sheesh. relatively new to TDi’s well diesels in general lol. My main concern rn is just mpg but I just want a little more push when trying to pass people. But maybe down the road that v6 might be something fun to look at
Bone stock A6/A7 are 240 HP / 428 LB-FT. (All the gen2 3.0 V6 are similar around 240hp/406tq). My A7 is now tuned and turbo back straightpiped and pulls real hard. I can get 40MPG mixed driving with a 1000' elevation increase mid way on my commute IF I drive fairly gently (still 75-80). Mid/upper 30s if I run it hard. The BEW got 44 stock, RC1+ and the in it's current custom RC3 state.
 

Mozambiquer

Vendor , w/Business number
Joined
Mar 21, 2015
Location
Versailles Missouri
TDI
2004 VW Touareg V10 TDI, 2012 Audi Q7 V6 TDI, 1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI, 2005 VW Passat wagon TDI X3, 2001 VW golf TDI, 1980 VW rabbit pickup,
Any tunes you would recommend? I’ve been looking at Malone but I keep hearing about kerma. Not many videos out there on them though
I just got a tune from @burpod for my BEW. Its a huge boost and runs awesome!
 
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