2.0l BEW, 6sp, GTB2260vk, FMIC Custom Build Thread

[O.C.TDI]

Well I figure I will leave a little update...
Finally getting close to 10k miles on the new setup. Everything has been working flawlessly. I have returned to work, and thus have returned to my daily commute. The car is 100% daily driveable, in fact I enjoy it now more than ever, I rarely get to use the available power but it doesn't matter, cause it is always there ready and waiting.

I made a trip down to the Bay area for a GTG and was able to turn my first 800+ mile tank at 52.7mpg that included 150 miles of San Fran running around. Around town I have yet to see less than 44mpg.

I keep seeing people say that a 200hp TDI is not very drivable on the street and get worse MPG. I have a very different opinion. I have been running the same tune I dyno'ed with and have had zero regrets. So much of the driveability is in the tune, but the hardware plays a big part of it too, if you are pushing your hardware too far you start loosing efficiency and driveability.

I am planning on heading out to the dragstrip tonight, pending we don't get rained out again. I am hoping to see some numbers in the 14's or better. Hopefully I can get someone to go with me for some video and pics.
I have finally installed my summer tires, and traction is excellent, in second and third I am right on the edge of them breaking loose.

Since I am working again and have got some miles on the engine, I ordered my 4bar MAP and my injector plans are starting to materialize. Hopefully in the next month or so I can get them in and running. Then hit the dyno and get some more ET's.

I have my core cam waiting to be sent to Colt for a re-grind. I am doing the cam last since my fueling is currently maxed out I don't feel that adding the cam now will really show the benefit of it.

O.C.

 

[VWBeamer]

Awesome car, I really have an appreciation for the tuning went into the header and intake. The header is a work of art. I often wonder why someone didn't build a larger plenum for the intake, and you did. I'm guessing it is about 2 liters in size?

BTW, would not the car smoke more on the dyno because of less air flow going thru the FMIC.

hotter air= less O2= more smoke?

 

[O.C.TDI]

Heat soak wasn't an issue, it would have appear in the dyno plots, and all of them were the same +/- 1hp.

The dyno loads the engine different than the road does, plus since the car is stationary the smoke builds in one spot and is not dispersed over distance.

I did not build the intake, it is an OE VW part, I only modified it, ie deleted the EGR ports.

On side note... There was no racing for me tonight, motorcycle only event at the track. Maybe next weekend.
O.C.

 

[VWBeamer]

LOL, well that's why I have the disclaimer in my signature..

 

[O.C.TDI]

Alright. Finally made it to the track. Car handled it quite well. I was able to turn out 18 runs. The track wasn't very busy, as track conditions are lack luster, still too cold up here to get the track temps up.

These runs were all done on the dyno/daily driver tune, no exotic supplements, straight D2, nothing in the tuning has been optimized for racing, I did not remove anything from the car, trunk full of coats, small supply of tools, laptop, helmet, full size spare, all seats were in place. This is pretty much how the car is loaded everyday.

All runs were 28 psi, EGT's varied between 1510* and 1680*, not nearly enough fuel. IAT were at max 30* above ambient. After the first few runs while sitting in staging my IAT were around 80*, this was pushing EGT higher. I started running the A/C on the return road and in staging lanes to get the fan to kick on and pull air through the I/C, this helped a ton, my IAT would drop from 80*+ to 65* and hold them there while waiting in line. It was around 62* when I got there and around 55* ambient by the end.

Last year I made a few runs with my old setup, my best time was 16.416 @ 87.4mph. All runs made with that setup were around 16.5 with trap speeds around 88mph.

This year it was better.
Run#..............60'................ET...............Trap MPH
1................... 3.05............ 15.865........... 95.44
2................... 3.96............ 16.679........... 95.54
3................... 3.22............ 15.748.......... 96.25
4 RED LIGHT hard and did not record
5................... 2.57............ 15.408........... 94.77
6................... 3.25............ 16.028........... 93.69
7................... 2.61............ 16.073........... 92.50
8................... 2.75............ 15.628........... 93.83
9................... 2.39............ 15.325........... 91.39
10................. 2.69............ 15.504........... 94.39
11................. 2.61............ 15.488........... 93.95
12................. 2.66............ 15.426........... 93.75
13................. 2.75............ 15.538........... 94.23
14................ 2.52............ 15.252.......... 94.73
15................. 2.52............ 15.420........... 94.21
16................. 2.59............ 15.529........... 93.88
17................. 2.63............ 15.552........... 91.76
18................. 2.52............ 15.370........... 93.87

So my best ET was 15.252 @ 94.73 that is 1.1 sec. better than last year plus I was able to gain about 9mph in the trap. This is what I will use as my baseline for future runs as I finish the last few details up.

I doubt I will run more with the current setup, my lack of fuel is a severe handicap and causing EGT to run on the high side.

Thanks to oldpoopie for taking pics and hanging out. Maybe he will chime in on a spectators perspective.

As always if you want to debate and scrutinize my results please feel free to start another thread to hash things out.

O.C.

 

[Rub87]

order some r783

 

[O.C.TDI]

order some r783

Toooo small. Injectors are top of the list, the wheels are in motion.

 

[LeadSSled]

Very nice. Good MPH. All of your "slowness" is in the first 60 feet. If that car could hook for a good 60-foot time, 96 mph is good enough for at least a low to mid 14 scond 1/4 mile ET, maybe even high 13's. It is just very tough to launch these high-torque FWDs without sticky tires.

Not scrutinizing or debating - just pointing out that your results are more encouraging than you might think based on ET alone. The trap speed tells it all. Nice job! I love this project.

 

["Yes it's a Diesel"]

Once you turn the fuel up your car is going to haul some serious ass.

Have you ever thought about running some steelies with some drag radials for the track?

 

[PIERTEK]

Hi, That Is A Very Clean Job, Outstanding, Congrats I Wish I Could Achive A Finish Like That With Metal Welding And Fabrication, Also Knowing That I´m Not A Bread Maker Hahah Im A Mb Tech.
Thumbs Up From Spain.
Juan

 

[O.C.TDI]

I have all kinds of crazy plans for drag racing. Slicks, a second front bumper/crash bar to utilize the entire FMIC. At the same time I am not building a drag race only car. I have plans to actually add wieght to the car in the form of sound deadening and some stereo equipment.
This car is being built with a mission. Comfort of a BMW or Merc. With the performance of a Camaro or Mustang, and fuel economy of a Prius.
I don't need the fastest TDI in the country or world, I want the best driver. What the point in having a fuel efficient car that you don't want to drive.

I am by no means unhappy with my results. Track is still too cold for good hook up. I have not tracked the car much, much less with the current setup. I would have been very happy if I could have touched the 14's but I still have time to practice. The car has it in it, the driver just needs to work on the launch.

 

[dieselpower04]

Very nice! Drop those 60' asap!

 

[silverbox]

I have plans to actually add wieght to the car in the form of sound deadening and some stereo equipment.
This car is being built with a mission. Comfort of a BMW or Merc. With the performance of a Camaro or Mustang, and fuel economy of a Prius.
I don't need the fastest TDI in the country or world, I want the best driver. What the point in having a fuel efficient car that you don't want to drive.

I am by no means unhappy with my results. Track is still too cold for good hook up. I have not tracked the car much, much less with the current setup. I would have been very happy if I could have touched the 14's but I still have time to practice. The car has it in it, the driver just needs to work on the launch.

Great work! I love your Mission statement. Look forward to hearing about the rest of your Driver (non power)mods.

 

[Farfromovin]

If I were you Travis, I'd remap 1st and 2nd to pull back the power a bit. That will help with launching a 388 ft/lb fwd diesel LOL. These cars are just hard to launch IMO. 1st gear is just useless, but 2nd seems just a bit too tall to start in. Nice trap speeds though!

 

[vwmikel]

If I were you Travis, I'd remap 1st and 2nd to pull back the power a bit. That will help with launching a 388 ft/lb fwd diesel LOL. These cars are just hard to launch IMO. 1st gear is just useless, but 2nd seems just a bit too tall to start in. Nice trap speeds though!

This isn't so much of a problem with a larger turbo. The load just isn't there to make full boost in lower gears. It's actually a pretty effective form of traction control

 

[im570rm]

i thought lowering the power in low gears is possible only on gas ecus

 

[O.C.TDI]

The car will hook and go. I still have to learn where the sweet spot is for the balance of power and traction. That is part of why my launches and trap speeds vary. Finding optimal shift points and so on. When it does break tration at the start it is hardly noticable, I found I had to listen for the tires to actually squeal since it has zero wheel hop and hardly any torque steer, but by he time they squeal it's too late.

At this point I have no need to alter the tuning for the current setup, especially since things are going to start changing again very soon. I have been more than pleased with all the results I have accumulated thus far, it has all worked exactly as planned so far, hopefully I can hit my target range and maintain the cars useability and fun factor. I currently hope to be doing final testing and tuning for the car by early August.

O.C.

 

[vwmikel]

i thought lowering the power in low gears is possible only on gas ecus

Some EDC16 ECU's have this ability as there are different throttle maps for each gear.

 

[VWBeamer]

Sweet. .

 

[dieselpower04]

Some EDC16 ECU's have this ability as there are different throttle maps for each gear.

Yep! I've got that on mine! 1st and 2nd are dialed back

 

[TDIMeister]

Update! Where're the cam and 1200HFs?

 

[O.C.TDI]

Nozzles are on order. Cam is being sent out next week. Finish up exhaust in a couple weeks.
Things have been moving slow, as expected.

I have installed the 4bar map sensor. No tune change except for linearaztion.

O.C.

 

[mrchill]

Which 4 bar did you go with?

 

[O.C.TDI]

Which 4 bar did you go with?

This one.

It has Part Number: 03K 906 051 from VAG and comes from new 2.0L 16V Bi-Turbo TDI with 180hp.


Clipped from this thread... Thanks Alex
http://forums.tdiclub.com/showthread.php?t=261183&highlight=4bar

Straight bolt in for the small MAP boss, plugs straight in as well.
I got mine from ECS for less than $70, it did take them a month and a half though.

O.C.

 

[Farfromovin]

Plug n' play 4 bar? Nice! Added to favorites

 

[ryanp]

I think they are £40ish from the VW dealer over here, really wish i had waited a while and got one of these as mine cost me a small fortune!

 

[O.C.TDI]

TDIFest is over and I have some time to sit down and make an update.

8/22/10: Found tdisyncro selling a set of pd150 injectors, that he had some issues with for a good deal, they were send to DBW and set up with a new set of R783's. syncro had problems with these injectors firing properly, DBW went through them completely and sent them out to me to test.

8/26/10: Swapped in Colt stage 2 PD camshaft. Nice addition, engine starts and runs smoother than ever. I did notice a little butt dyno increase in power.

8/27/10: Removed exhaust system. Installed 3"x8" Vibrant turbo flex, to replace the cheap 3"x6" experimental flex section. Very noticeable reduction in resonant noise and vibration. Installed a catalytic converter (sort of), a couple of v-band clamps, a Aero turbine 3030xl muffler, and finished out the 3" exhaust over the axle. Car has a great sound, still very quite, but aggressive.
Between the cam and finishing the exhaust the car is incredibly smooth and quite. Almost creepy how smooth it is.

9/1/10: Removed my PD150 injectors and replace with the 150/R783 injectors. When I got it started it was misfiring on the number 1 cylinder. Talked with DBW and VWMikel and decided to run them for a few days to see if it would start firing on time.

9/2/10: Went back to Portland Speed Industries and strapped her onto the rollers again. It was still misfiring. Did some logs on the dyno, and turned some decent numbers. This was with the base file, just to get the car running with the new nozzles. We decided not to tune on it further until the injector problem is worked out.

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

Here is an overlay of the best previous run with the new run. Changes between the two runs: Cam, Over the axle exhaust, misfiring R783's, 4 bar MAP, opened up airbox a little, tune for 4 bar, injectors, and a bit more boost in the upper Rpm, tune is set at 32#'s.

Here is 2 of the runs from that day.

You can see the misfire on the plot. You can feel it in the car as well.
By this time I was out of time to change anymore on the car before Fest and drag racing. I decided I would go ahead and run at the track with the misfire. I really didn't want to but went ahead and did it anyway.

Here is my best time of the day. On slicks, D2 only
9/4/10
O.C.TDI:
R/T... .090 (best)
60'... 2.302
330...6.238
1/8...9.360
MPH...80.33
1000...12.031
1/4...14.278
MPH...100.78

8/22/10: A couple weeks prior to changes I was able to squeeze out this run on street tires.
R/T... .385
60'... 2.438
330... 6.590
1/8... 9.894
MPH... 77.00
1000'... 12.760
1/4... 15.149
MPH... 94.76

$3000= 6mph and 0.9 seconds


Here is a couple nice video links. Thanks FlyTDI Guy
http://www.youtube.com/watch?v=07M4lT9VbIs&feature=related

First run. First time on slicks.
http://www.youtube.com/watch?v=G8kBmkq4ZG0&feature=related

The following week after fest I replaced the R783's with my PD150's. My Firads finally showed up the same day. I boxed up the number 1 R783 injector, the Firads and another set of bodies to DBW. I should have them all back this afternoon and will get to start really testing injectors next week.

I will have 3 full sets of PD injectors. PD150's, R783's and Firad +100% over 150's.

O.C.

 

[shizzler]

426 lbf-ft from 2 liters of displacement... unreal.

Nice work man. Thanks for all the data!

Hope you get that misfire sorted out and find some more power.

So it was another $3000 just for cam, injectors and exhaust....?? Or does that count the slicks also?

 

[O.C.TDI]

Slicks as well.

Cam, lifters, bearings, seals, injectors, nozzles, flex, muffler, v bands, slicks, shipping, mounting.
No labor charges

O.C.

 

[TDIMeister]

I'm interested to follow up on the injector/nozzle issue you're having. I'm surprised Pete is even willing to entertain touching any nozzles that are not OEM or God's gift Bosios...