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

O.C.TDI

Veteran Member
Joined
Apr 29, 2007
Location
Oregon City, OR
TDI
04 Jetta TDI, 09' JSW TDI, 09' BMW 335d
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?

Not sure, but I'm leaning towards surge.
I hear it on the video, but while in the dyno room it wasn't as noticeable. My pd150 tune rode the surge line fairly close, yet I have only experienced surge once while driving. I was setting up to pass a slower moving vehicle on an 8+% grade in 5th gear at 2000 rpm with 21#'s at about 3,000' elev.

If you look at the boost reference it does appear to have a bit more boost earlier in the rpm range. I received a new file this morning and will be running logs this weekend.

O.C.
 

NHgranite

Veteran Member
Joined
Dec 8, 2010
Location
New Hampshire
TDI
2012 Passat CKRA
Could you post some info/photos of the battery mounted in the trunk?

Also, any progress with the stereo install?

Thanks !!
 

kooyajerms

grocery getter
Joined
May 5, 2004
Location
Pomona, Southern California
TDI
97 B4V (mine), 11 x5 35d (hers) 04 V10 (that one you want), 2014 Q7 (mom's) 74 Shasta 1400
Travis, looking great! Do you run the dyno tune on the street or do you use a different one for the daily drivin'?
 

O.C.TDI

Veteran Member
Joined
Apr 29, 2007
Location
Oregon City, OR
TDI
04 Jetta TDI, 09' JSW TDI, 09' BMW 335d
Could you post some info/photos of the battery mounted in the trunk?

Also, any progress with the stereo install?

Thanks !!

Mine looks similar to CNB's trunk battery except mine is not in a box yet, (waiting for sound system to finish up the trunk details). I am running a Lifeline GPL-3100T starting battery, 100Ah 1300cca AGM battery with "00" welding lead for cables. Way overkill. I might put it in my Cummins and get a smaller Oddessy battery for the car.

I have not done anything more with the sound system yet, I am getting closer to starting that adventure but am waiting for March to do stereo and sound deadening since my windshield needs to be replaced and it will be easier to pull the headliner with the windshield out.

kooyajerms
Travis, looking great! Do you run the dyno tune on the street or do you use a different one for the daily drivin'?
I dyno and track the same tune I daily drive. I am not here to lay down inflated numbers, I want to show what can be done "safely" while retaining maximum driveability and longevity. I don't have sponsors or anyone helping absorb the cost of this project. So I can't waste time and money running tunes just to get big numbers. Same reason I don't remove anything from the car when I race at the track, my numbers are a representation of what my car can do everyday, because that is how I drive it.

O.C.
 

Farfromovin

Torque Addict
Joined
Apr 9, 2005
Location
Ventura, CA
TDI
03 Golf 2dr- PD150 6m
I dyno and track the same tune I daily drive. I am not here to lay down inflated numbers, I want to show what can be done "safely" while retaining maximum driveability and longevity. I don't have sponsors or anyone helping absorb the cost of this project. So I can't waste time and money running tunes just to get big numbers. Same reason I don't remove anything from the car when I race at the track, my numbers are a representation of what my car can do everyday, because that is how I drive it.

O.C.
I like your style Travis :p
 

Conan

Veteran Member
Joined
Dec 2, 2010
Location
Denver
TDI
2003 GLS TDI
I would make sure that battery box is incredibly well secured. In a frontal collision, that battery would be like a cannonball to the back of the driver's seat.
 

MichaelP

Well-known member
Joined
Jul 10, 2008
Location
Happy Valley, OR
TDI
2000 Jetta ALH 5-speed
How did I miss this thread? BTW - if you are going to drag race at NHRA tracks and do not have sheet metal separating the trunk from the interior, then a marine battery box will not suffice. There is one plastic Moroso sealed battery box that is approved, otherwise it needs to be in a fully sealed metal enclosure.
 

O.C.TDI

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Joined
Apr 29, 2007
Location
Oregon City, OR
TDI
04 Jetta TDI, 09' JSW TDI, 09' BMW 335d
I am currently trying to get some time to get some numbers on the stock pd130 head I have on it now. My machinist has my next head and the big valves. Oldpoopie is in front of me in lane at the machinist. :(

The stock head appears to have a little bit more grunt on the bottom end, but it's hard to tell for sure. I hit a dyno day last week and my hp was 232 with no fan on the I/C which is right were I figured it would be but the torque was really low. 365tq. This was at a truck dyno day and the operator told me they could not load brake the dyno for me cause it was set to brake for RWD.

I should have some new dyno sheets next week on my normal dyno.

O.C.
 
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UsArmyTDI

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Jan 5, 2011
Location
fort hood texas
TDI
02 jetta (rip)
mrchill, i argee! question though, how is tq steer? comming from a mostly gas motor back ground my self, tq steer is a problem on most fwd cars making good power numbers.
 

O.C.TDI

Veteran Member
Joined
Apr 29, 2007
Location
Oregon City, OR
TDI
04 Jetta TDI, 09' JSW TDI, 09' BMW 335d
Torque steer is not an issue here. I spent as much time on the suspension and brakes as I did on the engine. Build the car to handle what you intend to throw at it before you go crazy on the power. To make a really nice daily driver you have to figure out where to compromise, constantly, handling vs comfort vs drivability vs power.

Alignment is also very important. I spent months setting my alignment up right were I wanted it.

O.C.
 

ryanp

Vendor
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Jun 22, 2008
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Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
What settings did you settle for on the suspension? I've spent a fortune on parts and once I'm back from holiday I'll be fitting them all and getting the whole lot aligned!
 

O.C.TDI

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Apr 29, 2007
Location
Oregon City, OR
TDI
04 Jetta TDI, 09' JSW TDI, 09' BMW 335d
I will have to check my files. It is fairly conservative. Mainly set up for low rolling resistance and to promote good tire wear since 97% of my driving is commuting, and summer tires cost over $200 a piece.
The front was easy, the rear beam is a pain in the a$$. Get alignment reading. Go take breaks and hubs off, shim each side to get were you want assemble and drive. Get another alignment. If it is not right, start over again. Repeat until you are happy or give up.
 

ryanp

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Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
I've got a Mk5 so everything on the rear has eccentric bolts for adjustment, not sure if that's better or worse TBH!! lol I was thinking of going parallel toe and 1degree camber all round initially and work from there, not much real data on the net regarding the actual settings as far as i can see!
 

jjordan11

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Joined
Jan 5, 2008
Location
Lehi, UT
TDI
1988 Audi 80 quattro PD130, 1982 Westfalia TDI
When do you plan on changing the injectors out to the Firads? After getting the Cylinder head back and doing another dyno? Should be interesting seeing the differences between the Bosio's and the Firads, I'm wondering how the smoke levels will be, better or worse.

I think I'm last in line at the machinist too :(, :).
 

O.C.TDI

Veteran Member
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Apr 29, 2007
Location
Oregon City, OR
TDI
04 Jetta TDI, 09' JSW TDI, 09' BMW 335d
ryanp- The mk5 is much easier to dial in. You shouldn't have near the trouble I did.
The the second head you sent is working flawlessly. Thanks again.

jjordan- I wanted to be putting the Firads in right now, but the head had different plans. I might throw them in the stock head after I dyno the stock head with the R783's. I am trying to get as much data through this process as possible. I am still debating whether or not to do the big valves, I hate to pull the pistons out and have them cut and coated again.

I will try to sit down this weekend and post a proper update. Hopefully I can get off work early and hit the dyno Friday.

O.C.
 

Rub87

Top Post Dawg
Joined
Dec 10, 2006
Location
Belgium
TDI
Ibiza '99 90HP
mrchill, i argee! question though, how is tq steer? comming from a mostly gas motor back ground my self, tq steer is a problem on most fwd cars making good power numbers.

Killed a wheel last week when I finally did again some km's with my ibiza (polo mk3 chassis), just overtook a car in 4th on dry straight road and couldnt hold it on the road, went on the left side next to the road and then back on at around 160kph, guess something is definatly wrong with the alignment :rolleyes:
 

jjordan11

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Jan 5, 2008
Location
Lehi, UT
TDI
1988 Audi 80 quattro PD130, 1982 Westfalia TDI
I love all the data you are collecting, it is very helpful and interesting.

Regarding the valve pockets and the oversized valves, does Brian think much will have to be done to the pistons to clear the valves? I haven't done anything to my pistons, but I am planning on pulling them out to put in some better connecting rods. I should have checked the clearance when I had my valves here with me :(.
 

ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
Killed a wheel last week when I finally did again some km's with my ibiza (polo mk3 chassis), just overtook a car in 4th on dry straight road and couldnt hold it on the road, went on the left side next to the road and then back on at around 160kph, guess something is definatly wrong with the alignment :rolleyes:
Haha, I had a similar problem in the Mk3 whilst i was doing the logs for you!
 

TDIsyncro

Veteran Member
Joined
Nov 14, 2005
Location
Saskatoon, SK
TDI
Audi/TDI x 2
I love all the data you are collecting, it is very helpful and interesting.

Regarding the valve pockets and the oversized valves, does Brian think much will have to be done to the pistons to clear the valves? I haven't done anything to my pistons, but I am planning on pulling them out to put in some better connecting rods. I should have checked the clearance when I had my valves here with me :(.
yes...excellent data and work!

It should mainly be an issue of larger dia reliefs. Depth should remain same with valves seat with faces flush to head surface.

OC, if you want to consider a future cam option, an extra .6mm deeper or so might be a good idea. Then the bowls (CR reduction) can be done at same time. I might be able to prep a BHW set for you ahead of time if you want to do some sort of exchange, that way your engine does not have to sit in pieces for weeks. Only downside is my spare set is used, not spanky new like yours. :eek:
 

mrchill

TDIClub Enthusiast, Super Secret Diesel Ninja Vend
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MASS! home of THE WORLD SERIES CHAMPION RED SOX! x
TDI
96 B4v red \ 98 Mk3 green\98 Mk3 Jetta black\ 99 Mk4 Jetta green x2\ 99 Mk4 Golf silver x2\ 99 Mk4 Jetta black\ 97 B4 sedan green\04 JSW gold\03 JSW silver
ryanp- The mk5 is much easier to dial in. You shouldn't have near the trouble I did.
The the second head you sent is working flawlessly. Thanks again.

jjordan- I wanted to be putting the Firads in right now, but the head had different plans. I might throw them in the stock head after I dyno the stock head with the R783's. I am trying to get as much data through this process as possible. I am still debating whether or not to do the big valves, I hate to pull the pistons out and have them cut and coated again.

I will try to sit down this weekend and post a proper update. Hopefully I can get off work early and hit the dyno Friday.

O.C.
Oversized may be an improvement....but I am still not sure its enough to warrant the cost. I'll let you know when I get mine back together and resume testing. I've had them in for a couple of years not....but too many engine and turbo configurations for proper back to back testing....
 

O.C.TDI

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Apr 29, 2007
Location
Oregon City, OR
TDI
04 Jetta TDI, 09' JSW TDI, 09' BMW 335d
So I will give some details to the last couple months.
Back in February I noticed some white smoke at idle when cold, this problem slowly got worse, I babied the car back and forth to work for 2-3 months. I figured it was either a crack in one of the ports or the head gasket. I figured I would try swapping in studs if the bolts weren't cutting it, thanks to TDISyncro for the research and info. I got the stud's here and realized the stud nut interferes with the cam caps on a PD. Had my machinist turn the nuts dow to fit properly. During this time I also had ryanp send me 2 PD130/150 heads, one core and one that was taken off a running car. Sent the core to the machinist and cleaned up the good one.

With everything ready to go for either situation, I tore the head off. The head gasket looked perfect, no signs of coolant loss. So the PD150 head bolts were holding my power levels just fine.

A flashlight in the port showed traces of coolant crust in 1 exhaust and 1 intake port. This head had 22k miles on it when it started to fail. I figure this happened from thermal stress on an aggressively ported head.
So plan 2 starts. Swap all my parts onto the new to me head and put the car back together with the new ARP studs torqued to 105'#s. I would have run PD150 bolts again without hesitation, except I had already paid for the studs and machining. Plus I will be doing another head swap and can reuse my studs.

All back together and driving fine. The butt dyno was telling me there was a little tiny bit less top end.

The real dyno confirmed this as well. I hit two different shops with the same model dyno and came up with matching numbers.

Here is what I turned at a dyno day with no fan.



I couldn't believe the torque loss. HP was on target with my feelings but the TQ seemed wicked low since my lowest TQ with ported head and PD150 injectors got me 388wtq.

I discounted this run as inaccurate since it was not on my standard dyno.
Today I went in and made passes on my normal dyno with my normal operator.

Same tune and what not from previous runs only difference is timing was -1.0 today vs. the previous with timing at +0.5
And of course this is with a stock head



I also hit the drag strip this last weekend and pulled a 14.5@100mph on my street tires. This was pretty much an identical run to my last one with the ported head and street tires at TDIFest. It wasn't noticeable at the track since I am only down a couple HP in the upper rpm range.

Right now I am working on getting a new set of pistons machined up so I can run my new big valve PD head. I am hoping to be done with the bottom end and head swap by August so I can get my numbers and continue with injector testing and be all done with this thing before August 20th for a big NHRDA event here in town.

O.C.
 
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