1.9TDI Quattro Turbo/Supercharger build

adamss24

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Nov 2, 2005
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Great Britain
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audi a4 2.5 tdi 98 quatrro 6speed
Did you try using a bit of Brake cleaner spray to see if it’s going to prime itself ? While caution is needed it’s the easy way to prime the engine ! Also replace the plastic thermostatic tee if you’re still on factory fuel filter, I had them- on a few occasions - block after doing service to cars and no start condition just as in your case ! New valve fixed it !
Nice progress by the way, nearly there !
 

miniCotulla

Veteran Member
Joined
Dec 28, 2019
Location
Austria
TDI
Passat B5 1.9TDI PD
Did you try using a bit of Brake cleaner spray to see if it’s going to prime itself ? While caution is needed it’s the easy way to prime the engine ! Also replace the plastic thermostatic tee if you’re still on factory fuel filter, I had them- on a few occasions - block after doing service to cars and no start condition just as in your case ! New valve fixed it !
Nice progress by the way, nearly there !
Yes, and the head was full of diesel when we pulled the injectors.
 

tdi_my live

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Jul 24, 2011
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Germany
TDI
Skoda Fabia
air is available? what does the mwb04 show in the sync angle? I know it won't start. What software is used for this, already a modified one? If so, try starting with an original file.
 

miniCotulla

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Dec 28, 2019
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Austria
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Passat B5 1.9TDI PD
air is available? what does the mwb04 show in the sync angle? I know it won't start. What software is used for this, already a modified one? If so, try starting with an original file.
Yes air is available. -2.8° should be close enough to start. Already tried different stock ecu.

We have the suspicion that we removed a little too much material from the injector seats and the diesel is going into the engine oil instead of the injectors. (typical wear marks for PDs were present before). Oversized o rings are already in the mail.
 

miniCotulla

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Dec 28, 2019
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Austria
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Passat B5 1.9TDI PD
New update, still no fuel, tandem pump delivers 2 bar, in spec. We checked the signal from the ecu, the wiring harness, everything is correct. Is there a specific Torque Value for the magnet valve on the side of the injector? We just turned it as far as it would go. Maybe that's too tight and the valve gets closed shut?

 

miniCotulla

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Joined
Dec 28, 2019
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Austria
TDI
Passat B5 1.9TDI PD
New update, still no fuel, tandem pump delivers 2 bar, in spec. We checked the signal from the ecu, the wiring harness, everything is correct. Is there a specific Torque Value for the magnet valve on the side of the injector? We just turned it as far as it would go. Maybe that's too tight and the valve gets closed shut?

This was the problem, we loosened these caps now it starts with stock ECU file.
 

miniCotulla

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Dec 28, 2019
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Austria
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Passat B5 1.9TDI PD
New update, we got three injectors working, one of the 200% nozzles is clearly not working, no injection still, no heat on exhaust manifold. Looking into buying a whole new set with ether 160s firad or Wuzetem nozzles, MFPerformance even sells 220% Firads now but only nozzles not whole injectors.
 

miniCotulla

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Joined
Dec 28, 2019
Location
Austria
TDI
Passat B5 1.9TDI PD
New Update, after multiple broken ECUs, yesterday the first drive with stock injectors was successfull, sadly we don't know how much boost the supercharger delivers as we then had to use a stock ECU (Map Sensor reads garbage). Volvo electric Power steering is like stock, not too light or to hard. Clutch is very light but you notice the lack of a DMF at lower rpms. The exhaust is really quiet, stock is louder than this 🤣 the water intercooler does it's job very well, no more than 35C° even with outside temps at 30
 

adamss24

Veteran Member
Joined
Nov 2, 2005
Location
Great Britain
TDI
audi a4 2.5 tdi 98 quatrro 6speed
New Update, after multiple broken ECUs, yesterday the first drive with stock injectors was successfull, sadly we don't know how much boost the supercharger delivers as we then had to use a stock ECU (Map Sensor reads garbage). Volvo electric Power steering is like stock, not too light or to hard. Clutch is very light but you notice the lack of a DMF at lower rpms. The exhaust is really quiet, stock is louder than this 🤣 the water intercooler does it's job very well, no more than 35C° even with outside temps at 30
Congratulations on getting it to run, now it’s just ironing the bugs out of it ! Well done !
 

Mozambiquer

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Mar 21, 2015
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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,
New Update, after multiple broken ECUs, yesterday the first drive with stock injectors was successfull, sadly we don't know how much boost the supercharger delivers as we then had to use a stock ECU (Map Sensor reads garbage). Volvo electric Power steering is like stock, not too light or to hard. Clutch is very light but you notice the lack of a DMF at lower rpms. The exhaust is really quiet, stock is louder than this 🤣 the water intercooler does it's job very well, no more than 35C° even with outside temps at 30
And we are all lookin forward to a video...
 

miniCotulla

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Joined
Dec 28, 2019
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Austria
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Passat B5 1.9TDI PD
Next Problem: Map Sensor diagnostic limits

If I change linearization to

921 --> 6000
102 --> 500

according to Bosch datasheet(0 281 006 282) this should be correct.

If I leave diagnostic limits stock VCDS reads correctly. If I change diagnostic limit to 6bar and offset to 425 I get double the atmospheric pressure even on the bench (no sensor attached) and in the car. I used the same formula for 4 bar sensor in the past no problem. For 4 bar I used offset 638. what could be the issue here?
 

Machineman

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ontario canada
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2007 RS4 Titanium 3.0TDI & 2013 Touareg TDI & B6 S4 BHW Swap Biturbo
Wow great work such a unique build!! I hope you have good luck with Turbosystems turbo. I bought a stg3 BB for my 3.0tdi and after 1000kms at 1.7bar. It makes a funny noise and now the shaft wobbling after a hard pull 😮💨 they won't even respond to my emails 🙄
 

adamss24

Veteran Member
Joined
Nov 2, 2005
Location
Great Britain
TDI
audi a4 2.5 tdi 98 quatrro 6speed
Wow great work such a unique build!! I hope you have good luck with Turbosystems turbo. I bought a stg3 BB for my 3.0tdi and after 1000kms at 1.7bar. It makes a funny noise and now the shaft wobbling after a hard pull 😮💨 they won't even respond to my emails 🙄
That sucks Kyle ! In Eastern Europe they are well regarded and many have made a lot of power with their turbochargers !! I hate buying hybrids made by someone else as you’re at their mercy when things go pear shaped !
I am on the lookout for a gte3071vzk and I will make it fit, it’s much easier to get a replacement chra than to deal with a turbo manufacturer that’s not answering emails and such !
I do hope you get the issue resolved as I am sure you paid a pretty penny on your turbo !
 

tdi_my live

Veteran Member
Joined
Jul 24, 2011
Location
Germany
TDI
Skoda Fabia
Next Problem: Map Sensor diagnostic limits

If I change linearization to

921 --> 6000
102 --> 500

according to Bosch datasheet(0 281 006 282) this should be correct.

If I leave diagnostic limits stock VCDS reads correctly. If I change diagnostic limit to 6bar and offset to 425 I get double the atmospheric pressure even on the bench (no sensor attached) and in the car. I used the same formula for 4 bar sensor in the past no problem. For 4 bar I used offset 638. what could be the issue here?
Sensor linearization is one thing. diagnostic expansion is another. I am currently on vacation. When I get back I can help. Here I don't have a laptop with Winols and everything you need.
 

miniCotulla

Veteran Member
Joined
Dec 28, 2019
Location
Austria
TDI
Passat B5 1.9TDI PD
Sensor linearization is one thing. diagnostic expansion is another. I am currently on vacation. When I get back I can help. Here I don't have a laptop with Winols and everything you need.
I know those two are separate things, but I did both before on a 4 bar Sensor, the same changes for 6 Bar results in really funny behaviour to a point where I think there is some kind of error happening with the ECUs logic trying to process the calibration for the higher diagnostic values.
 

tdi_my live

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Jul 24, 2011
Location
Germany
TDI
Skoda Fabia
For 400hp you need minimum 2500mg air to be smokefree. Wath absolut pressure you think about? Min 5000hpa?
 

tdi_my live

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Joined
Jul 24, 2011
Location
Germany
TDI
Skoda Fabia
do you use a mass air flow sensor? I would use one up to the limit of the sensor so that you don't fly completely blind because of the large nozzles to keep an eye on the smoke. Then switch it off and tune it to the target performance.
 

miniCotulla

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Austria
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Passat B5 1.9TDI PD
do you use a mass air flow sensor? I would use one up to the limit of the sensor so that you don't fly completely blind because of the large nozzles to keep an eye on the smoke. Then switch it off and tune it to the target performance.
No MAF
 

tdi_my live

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Jul 24, 2011
Location
Germany
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Skoda Fabia
the linearization is righ for 600kpa sensor
921 --> 6000
102 --> 500

Can you post your used Softwarenumber 038906019?? and the Version ???? and Coding is 00003 for 4wheel?
 
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tdi_my live

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Location
Germany
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Skoda Fabia
you just don't tell me your software version.
It is not enough to change the gradient to 425 (16bit). To do this, the display number and the standardized value must be adjusted in 8bit. available 3 times in total.
 

miniCotulla

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Dec 28, 2019
Location
Austria
TDI
Passat B5 1.9TDI PD
you just don't tell me your software version.
It is not enough to change the gradient to 425 (16bit). To do this, the display number and the standardized value must be adjusted in 8bit. available 3 times in total.
I have 038906019EP.

I changed these 3 maps to 60000 from -238 (Limit 1 and 3) and 29960 (Limit 2):


And this one to 425:


My Map Sensor readings were doubled (1.8 bar with engine off) and also my atmospheric pressure was off but not by the same amount, i suddelny showed ~1,2 bars

I also tried only changing Limit 2, still the same, also tried different values like 59960 (similar to stock where it's not exactly 30000), this resulted in non numeric values without unit(mbar) showing in VCDS. It was something like "15636 E" instead of "980 mbar", I guess the ECU ran into some kind of exception.

What am I missing?
 

tdi_my live

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Location
Germany
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Skoda Fabia
I do not know where to start. you have an “old” software version because your limit is already at 2601hpa. There are newer ones with Euro 4, for example the BLT, it's a little easier to explain because the limit is only at 3060hpa.
The addresses in your program are therefore incomplete. The address 631BA +631BB (8bit) must also be changed, otherwise the limit will still be too early. then it is important to look at the addresses 631B4+631B8+631BA+631BB+631E0 in 8 bit and not in 16 bit. These have to be changed and the equivalent value to 425 (in 16bit) so that it fits again for 6000hpa.
It's best if I finish it for you and send you the file by email. If you can send me the email address via PM.
 

arazvan2002

Veteran Member
Joined
Sep 28, 2010
Location
Romania
TDI
Audi A4 B6 1.9TDI AVF quattro
I have 038906019EP.

I changed these 3 maps to 60000 from -238 (Limit 1 and 3) and 29960 (Limit 2):


And this one to 425:


My Map Sensor readings were doubled (1.8 bar with engine off) and also my atmospheric pressure was off but not by the same amount, i suddelny showed ~1,2 bars

I also tried only changing Limit 2, still the same, also tried different values like 59960 (similar to stock where it's not exactly 30000), this resulted in non numeric values without unit(mbar) showing in VCDS. It was something like "15636 E" instead of "980 mbar", I guess the ECU ran into some kind of exception.

What am I missing?
You can't fix it in vagsuite. Try winols or send me the file (an ori file or whatever) and I will help you. You have to change the formula(s) from 18 255 to 8 157 (for 4bar) and facctor 637.
 

krook

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Joined
Jan 13, 2021
Location
Hungary
TDI
A4 B5 AWX, A4 B5 AFN
i can also help out if you send a file, or i can create one from a stock one if i know the correct part number for your ecu. very interesting thread, please keep us posted. if you want to learn yourself how to do it in winols, there are great threads over there at ecuconnections forum. i used to do it as described above, however i was introduced to a method that is easier to see through (by defining a map around all of the factors first).

also next time i don't recommend ever removing the MV caps on the unit injector, unless you can source the green oring thats underneath it. we ran into issues with that and it caused leaking and bad starts / low performance. also we tested these nozzles very long term (50k+ km) and they are still fine (corrections read max 0.3, engine runs smooth and acceptable egt): https://www.recambo.de/Injector-150-Flow-For-VAG-Pump-Nozzle-12-14-19-20-25-Tdi-2V
we found these are a good alternative to the hard to source firad/wzm nozzles, ships within a week from germany. to give you a comparison, these jettex +200% flow similarly to firad 160%. i suspect it's because the firads use a different, shorter needle, therefore they're able to deliver even more.
 
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krook

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Jan 13, 2021
Location
Hungary
TDI
A4 B5 AWX, A4 B5 AFN
It was already solved by tdi_my live. Now it reads correctly and over 3 bars in VCDS.
that's great! i just edited my comment to add some more advice, speaking from our experience. i can show videos in pm of pop testing the nozzles
 

miniCotulla

Veteran Member
Joined
Dec 28, 2019
Location
Austria
TDI
Passat B5 1.9TDI PD
i can also help out if you send a file, or i can create one from a stock one if i know the correct part number for your ecu. very interesting thread, please keep us posted. if you want to learn yourself how to do it in winols, there are great threads over there at ecuconnections forum. i used to do it as described above, however i was introduced to a method that is easier to see through (by defining a map around all of the factors first).

also next time i don't recommend ever removing the MV caps on the unit injector, unless you can source the green oring thats underneath it. we ran into issues with that and it caused leaking and bad starts / low performance. also we tested these nozzles very long term (50k+ km) and they are still fine (corrections read max 0.3, engine runs smooth and acceptable egt): https://www.recambo.de/Injector-150-Flow-For-VAG-Pump-Nozzle-12-14-19-20-25-Tdi-2V
we found these are a good alternative to the hard to source firad/wzm nozzles, ships within a week from germany. to give you a comparison, these jettex +200% flow similarly to firad 160%. i suspect it's because the firads use a different, shorter needle, therefore they're able to deliver even more.
Those are not good at all, the first set of 100% recambo nozzles lastet about 1 year 15tkm, of the new 200% set even after cleaning the MVs one nozzle is already dead
 

krook

Veteran Member
Joined
Jan 13, 2021
Location
Hungary
TDI
A4 B5 AWX, A4 B5 AFN
hmm, interesting. have you pop tested the nozzles before installing? in my experience, sometimes one nozzle comes dead from factory. but that is the same for firad/wzm/recambo. as i said, we have sets of 150% running for a really long time, also recently installed 50% in one of the cars like 5k km ago, both are fine. but thanks for sharing your experience!
 
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