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

[shizzler]

Wait a sec. These were done in 4th gear, right? Which is still around a 1.0 gear? What is your final drive?

I'm trying to calculate your BMEP at torque peak... and even moving the 4th and final drive ratios around quite a bit, I am calculating far less torque than what is on your plot from the HP curve.

 

[TDIMeister]

You don't need RPM to determine BMEP if you already have torque.

~425 lb.ft in a 1968cc engine gives 36.8 bar BMEP.

 

[O.C.TDI]

Final drive is 3.238
4th is .972

Compression ratio is about 18.4:1

These runs were on the same inertia mode Dynojet as the previous runs.

 

[shizzler]

Oh, right. I was working in a contrived spreadsheet I have that starts from a HP input (thus requiring rpm to get to torque). But it is always still good to double check rpm-HP-torque for accuracy.

I'm not so sure about your dyno operator's # choices to create that dyno plot.

With your gearing, at 60 mph = 2541 rpm (assuming stock tire size), ~185 HP is ~382 lbf-ft, not >420....

hmm.

 

[turbobooster]

I think you're reading the horsepower number from one run and comparing it with the torque of a different run. There are two runs on that dyno sheet.

Edit: I was referring to the first dyno spreadsheet. On the second spreadsheet, I see what you're saying. I think the rpm versus mph must not be quite right, as the first sheet has rpm instead of mph along the x-axis and looks correct.

 

[dieselpower04]

WOW. Color me impressed!! And jealous!

 

[O.C.TDI]

All actual runs were with RPM not MPH. The MPH only showed up when they overlay them. I am assuming that the MPH is not accurate.

 

[shizzler]

Ah, ok. I was using the second plot. Thank goodness, I didn't want to rain on your 426 lbf-ft parade here.

Seemed like your spool was a little slow from the mph-rpm conversion on the second plot, but I'm glad that's wrong.

Again, just awesome. I bet the 60-100 mph pull just rips.

 

[danielhf]

I'm waiting to see results for the Firad +100%s. I waited for months for them and just went for the R783s in the end when they never became available. Then I got the email about them a week after I put the R783s in. Ugh.

Let's see what those put down. 300whp? I wouldn't be that surprised.

 

[bussso]

BHW pistons are more resistant or less than the Pistons pd 150? bear many hp? because they cost much more than the Pistons pd 150? $ 800 instead of the pistons BHW $ 330

 

[Farfromovin]

BHW's should provide more even temp distribution throughout the entire piston compared to older pd styles. There is considerably more area to machine the bowl for custom compression ratios before worrying about thickness above the oil holes. And they're BIGGER lol!

 

[O.C.TDI]

On with the next update...

I have injectors!!! It looks like I have become a bit of an injector whore. Still have the PD150's in at the moment.

R783's in PD150 injectors

The #1 injector was reset, now it can join the others again.

Firad PD150+100% in BEW bodies


Set them out for a little PD nozzle porn shoot.


Hope to put the R783's back in this week. Fingers crossed we have found the culprit and can continue testing them. If they don't workout this time I will go straight to the Firads.
Hats off to DBW, he has been very easy to deal with and full of information, lightning fast turn around on his services.

O.C.

 

[Farfromovin]

INJECTOR WHORE lol! Man, I was hoping you were going to have a 3rd set of 150 bodies. That's fine, the BEW's will work too. I don't think anyone really "knows" performance differences between bodies with large nozzles. It worked for Ben with his R783's so I'm sure the Firads will be fine. Here's hoping to 250 and 300! Hope the dyno guys are giving you a discount by now.
--edit-- Did you have DBW set up your R783's for standard values? I'm wondering how your new R783's data looks compared to mine:

 

[dieselpower04]

OooooHhhhh BEW/R783s!!! I wanna know #s!!

 

[O.C.TDI]

Far: I too was hoping for 150 bodies for the Firads, just to keep a level playing field, but since I am absorbing all the associated cost with doing these tests I opted to save a few pennies and use my old BEW injectors.
My flow specs are legible in the pictures. Click on them and look at the full page view in the pic server. I don't have enough time right now to copy them down.

Dieselpower: the R783's are in 150 injectors. The Firads are in the BEW's.

O.C.

 

[TDIsyncro]

OC, I am hoping that injector is going to smarten up now. If it does not, I have a spare PD150 body I can send to DBW. Looking forward to seeing what all the results are. Kudos to you for taking the time and expense to make this happen and share the results! It will give some guidance to others on what to expect and plan for in builds.

 

[Farfromovin]

Interesting. DBW setup yours @175/280 and mine are at 180/300. NA PD owners appreciate your testing! I certainly understand first hand how much money are in those injector pictures.

 

[O.C.TDI]

We went a little under standard pressure. There is allot of testing to do. Depending on how they act I might have DBW do a few different setting by the time this experiment is done. Maybe we will be able to see how pressure affects power and drivability.

Syncro. Thanks for the injector. I will know if they are good to go soon.
I also appreciate your contributions, mine are drops in the bucket compared to yours.
Keep it up.

 

[dieselpower04]

Dieselpower: the R783's are in 150 injectors. The Firads are in the BEW's.

O.C.

Gotcha! DBW said in another thread there should be no difference in PD150/R783 vs PD100/R783.

You have a lot of fuel to play with!! I wish I had more turbo to play with!

 

[Farfromovin]

Bump for updates.

 

[O.C.TDI]

Bump for updates.

Update...
I haven't had time to touch the car since fest, aside from commuting to and from work. I have been insanely busy the last couple months and accidentally let my tags expire, so until I get it re-licensed it is sitting in the garage. Been driving the "Farm Truck" to and from work for the last week, it sucks! Its really hard to go from 43-45MPG in a comfortable car to 15-18MPG in the bouncy Redneck truck.

I can say that I am coming up on the 1 year anniversary of the build, to date I have had no real issues (fingers crossed) with the car or any of the parts.

I am hoping to have the car back on the road in the next couple weeks. Since my schedule is opening up a little now, I hope to continue with the injector testing soon.

O.C.

 

[O.C.TDI]

Here is the latest update.
On the 1 year anniversary of the new engine my lift pump failed and left me to tow the car home from work.
I replaced the lift pump and while I was at it went ahead and replaced the tandem pump and injectors. Since I am trying to test all these injectors as accurately as possible I figured I would rule out any other potential failure points.

So with the R783's back from DBW, the misfiring #1 injector has been fixed and is functioning flawlessly. Injector balance is good.
First impressions with the R783's versus the PD150's is that smoke is reduced and the car is much more responsive, the turbo spools up a bit faster in the daily driving, and the top end has even more meat than it used to. We did not change the tuning since the last R783 pulls, since they were not functioning properly, this is still a base file to get the injectors running. I will be doing some logging and Mike will make some changes to the file. We both feel there is a bit more power in these nozzles without pushing the duration.

Here is the best previous run with the misfire over today's best run.




Here is today's 3 runs.
Run #1- 246.86hp 435.29tq
Run #2- 247.06hp 427.30tq
Run #3- 248.04hp 433.51tq



Not a big change in power, but the lines are much better looking.

Here is the video from today.

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

I will be daily driving and fine tuning the car until the track opens, then I will get some more 1/4 mi times, another trip to the dyno. Then swap in the Firad's and start the injector test dance once again. After all that testing we might experiment with different injector pressure settings. We will see if I can refrain from getting burned out.

O.C.

 

[Fix_Until_Broke]

Amazing - more low RPM power than just about any TDI and over 200 HP from 2500 RPM on out.

 

[dieselpower04]

I love that you get full spool @ 2250 rpm!!! 35 psi too!! DROOOOOL!!

 

[Farfromovin]

Outstanding for an "initial" tune!

 

[oldpoopie]

Travis, was that your factory original lift pump?

 

[O.C.TDI]

Travis, was that your factory original lift pump?

Yes, 6 years 112,000 miles.

 

[VWBeamer]

sweet

 

[jjordan11]

That's smooth, I just watched the video and it really doesn't smoke much. Do you know how much bhp it's putting out? I could guesstimate but it would be interesting to see how much it was putting out if measured how the Europeans measure theirs.

 

[Farfromovin]

In all the runs, during spoolup I hear a little chirping. Is that the tires fighting the rollers or a little bit of compressor bark going on?