287whp 2.0 TDI Jetta and still climbing...

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 ........
I already have a full build thread here but figured the 'Power Enhancements' should be in here since not many people look at the Picture Gallery for power mods.

The Engine is a European 2.0 16v TDI PD140 (BKD Code).

We will start at the end

We had the Jetta on Thor's Hub Dyno on Saturday for the NoSmokeNoPoke.com Launch Day.



This was with a some mapping tweaks (still not quite finished) but no more hardware upgrades.

We ended up with 287hp and 425Ft/Lbs at the Hubs. If you assume 10% transmission losses (it has been more like 20% on Shark's BaPro Dyno), you are looking at 316bhp and 468Ft/Lbs at the Flywheel.

___________________________________________________________________

These are the modifications we have done to get us to this level:

EGR Delete Kit:



GTB2260VK Turbo Kit with 3" Downpipe:




Intercooler Pipe Kit and S3 Intercooler:



Milltek 2.75" System (designed for Jetta GLI):




We then took it to the DYno. This is Standard vs Remapped vs Turbo Kit/Exhaust and Intercooler


We then fitted a Sachs SRE SMF and Sintered Disc:

http://i1209.photobucket.com/albums/cc394/darkside-developments/Jetta 2L 16v TDI BKD/SREClutchFW.jpg

and Peloquin LSD:

 
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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 ........
Next was a set of Bosio R1287 Nozzles:



We took it to the Dyno and got 301bhp & 440Ft/Lbs:



Jetta at Santa Pod (GTi festival 2011)



I managed to put in exactly 20 runs back to back without even a hiccup! All the runs had a terminal speed of over 100mph even when I selected reverse or had the odd missed gear!! As this was my first time out drag racing launching was the main issue so there are still a few tenths to gain and a less corner friendly suspension setting might help too but I’m happy as it’s exactly as it drives on the road!

The best run was a 13.8419 and the best terminal speed was 105.43mph. AFAIK the Fastest FWD TDI of the day.
We missed the fastest TDI trophy by 0.4 sec. That went to a nice guy with a homebrew Mk2 Golf Synchro/Haldex sporting a PD150 Lump, Hybrid Turbo and 150bhp shot of Nitrous!!</SPAN>

Here are two slips:




Video on YouTube of the Jetta:

http://youtu.be/VihZNoYxGlo

That was a 14.4 @ 103mph.

We then took the Jetta to Shark Performance's Dyno to compare our results with the DynoDynamics we have been using:




301.2bhp and 440Ft/Lbs - DynoDynamics @ John Sleath
299.5bhp and 438Ft/Lbs – BaPro @ Shark Performance

Difference is ~0.5% overall so I would say our results are accurate

220km/h Limiter removed:


That is what we are up to now.




We believe ~315bhp is the safe limit for the GTB2260VK and the Bosio R1287 Nozzles. We are also running out of Air so the head is almost maxed out.
We think this is the level most people will take thier BKD Engines to. After this is gets expensive :)
The Engine Block is completely standard at the moment and despite our best efforts to kill it, we have had no issues at all. We just service it every 8000 miles and make sure all the fluids are topped up.
If we do find the limit of the Bottom End, we have some Rosten Rods on the shelf that we can fit no problem.

We have a Ported Head and Bigger turbo ready to go on. Trying to choose between the GTB2263VK or GTB2563VK we have had made. Only time will tell.
We also have some bigger custom Injector Nozzles on their way to us and will be making a custom camshaft if required too.

We have some other secret plans as well, you will just have to wait for them.

Hope it has been an interesting read for everyone. I will update as we make more progress.

Thanks

Ry
 
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JasonCZE

Member
Joined
Apr 30, 2010
Location
Czech Republic
TDI
Ibiza 6K2 Sport 100kW
Just for curious, another BKD engine by Dieselpower.cz - 253HP / 534Nm


Mode list:
- injection nozzles Fratelli Bosio 1287
- hybrid turbocharger DT
- DIESELPOWER software

nothing more. Modification is from year 2009, dynorun 14 days ago.
 

Seatman

Top Post Dawg
Joined
Apr 23, 2010
Location
Scotland
TDI
2007 Seat Alhambra 2L tdi
I like the vid on your website Ryan where you hit reverse first lol and still went like a rocket, me want. :D
 

bhsramz

Veteran Member
Joined
May 12, 2009
Location
DFW
TDI
2013 Passat (sold); 2005 Golf 6MT and GTB2260 (sold); 2005 JSW; 2004 Jetta; 2010 Touareg w/ Air
Looks like you have been having fun, Ryan.
 

RudolfDiesel

Member
Joined
Aug 5, 2009
Location
Europe (A)
TDI
Das Auto
Very impressive power gain ...
Do you also have logs where we can see SOI and duration ? Or are this specific values "top secret" :) ?

Do you have any problems with your clutch or with the gear box ?
AFAIK the SRE clutch is able to hold ~530Nm of torque ... and the gearbox should be much weaker ... just asking because I heard that MQ350 gearboxes break much "earlier" than 590Nm ...

Regards
 

mlemorie

Veteran Member
Joined
Aug 15, 2009
Location
Romulus Michigan
TDI
2004 Jetta
It seems like BKD software issues I used to see on here have been worked out. I may need to re-think my ARL powered chevette project :D
 

NoJoke

Veteran Member
Joined
Apr 11, 2003
Very impressive! I hope to achieve those numbers! Is it me or should the 60' times be better? Traction issues:D or driver issues:p
 

vwmikel

Vendor , w/Business number
Joined
May 5, 2005
Location
Las Vegas, NV
TDI
'94 Golf Sport TDI
It seems like BKD software issues I used to see on here have been worked out. I may need to re-think my ARL powered chevette project :D

What software issues? As far as I know, it is just the 170hp versions of this engine which had a Siemens ECU that are more of a problem. This is just EDC16 (though a different variant from those in the US).
 

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 ........
Very impressive power gain ...
Do you also have logs where we can see SOI and duration ? Or are this specific values "top secret" :) ?

Do you have any problems with your clutch or with the gear box ?
AFAIK the SRE clutch is able to hold ~530Nm of torque ... and the gearbox should be much weaker ... just asking because I heard that MQ350 gearboxes break much "earlier" than 590Nm ...

Regards
If I were the man on the street I would have no problem giving this, but too many people would use it to their advantage commercially so I will keep those private if that is okay.

We have had no issues with the Clutch slipping, we have the Sintered Kit that is rated to 600Nm (440Ft/Lbs) but we have always found Sachs are conservative with their estimates. If it slips I will swap it for a SouthBend Stage 3 :)
We have also not had any issues with the 6 Speed Gearbox, we have fitted a Peloquin LSD and strengthened the shifter forks. It took 20 runs up the Drag Strip no problem!

Thanks for the comments guys, yeah the 16vs give us some benefit!

NoJoke said:
Very impressive! I hope to achieve those numbers! Is it me or should the 60' times be better? Traction issues
or driver issues
Both :eek: We are going to Pod again in April to hopefully improve the times!

Yep as Mike said there are no issues tuning the EDC16 ECU.

Had a few PMs about the spec, here it is complete:

2.0 16v BKD PD140 Engine

Darkside Developments GTB2260Vk Turbo Kit with Tubular Stainless Manifold and 3" Downpipe
Darkside Race 16v PD Injectors
Audi S3 Intercooler with Alloy End Tanks
Darkside Alloy Intercooler Pipework Kit
Darkside EGR Delete Race Pipe (Retaining ASV)
EGR Cooler Delete
4 BAR MAP Sensor
Milltek 2.75" Non-Resonated Exhaust System with Twin 76mm Jet Silencer
Darkside Developments Re-Map with MAF and EGR Delete

Current Figures
301.2BHP & 440Ft/Lbs - Race PD Injectors

Previous Dyno Results
235BHP & 330Ft/Lbs - Turbo Kit, Exhaust, I/C Kit & EGR Delete
166.6BHP & 285Ft/Lbs - Remap
134.8BHP & 255Ft/Lbs - Stock

Best 1/4 Mile Times
13.8419 @ 104.70mph and 14.1687 @ 105.43mph

Present Mileage - 117,000
Mapped @ 109,000
Turbo Kit @ 111,000
Injectors @ 115,500

PD170 BMN Long Ratio Gearbox with Strengthened Shifter Forks
Peloquin Limited Slip Differential
Sachs SRE Single Mass Flywheel with Sintered Paddle Clutch
Polyurethane Filled Dog Bone Bushes
PU Filled Gear linkage Ends

R32 Front Brake Calipers
R32 345mm x 32mm Front Brake Discs
Genuine Audi S4 Front Pads
TyrolSport Caliper Stiffening kit
R32 Rear Calipers
R32 310mm x 20mm Rear Brake Discs
Genuine VW Rear Pads
Eos 3.2 FWD Rear Splash Guards
Silver Zinc Plated Calipers

KW V1 Inox Coilovers
Audi TT Front and Rear Top Mounts
Audi TT Alloy Front Wishbones with Solid Bushes and Adjustable Ball Joints
Audi TT Alloy Front Hubs and Alloy Track Rods (26mm Wider Track)
Super Pro Console Bushes for increased Castor
Subframe Spacer Kit
Audi TT Driveshafts
Stock 19mm Front ARB
Audi TT Rear Axle with Alloy hubs (30mm Wider Track)
Passat R36 21.7mmx3.6mm Rear Anti-Roll bar

Audi S4 'Avus' 18”x8” ET45 Wheels Powdercoated Hyper Black
Uniroyal Rainsport 2 225/40/18 Tyres
Genuine VAG Wheel Bolt Caps
R32 18" Spacesaver Spare

Golf GTi Front bumper with Summer grills
Jetta GLI Rear Valance
Hella Projectors with Lamin-X Gun Smoke Tint and Osram Nightbreaker Bulbs
Smoked Rear Lights
Smoked Reflectors
Smoked Indicator Lenses
Pressed Numberplates
Rolled and Flared arches
Black VW Emblems

Leather Sports Seats
Scirocco R / Golf VI Multifunction Steering Wheel
Passat CC Headlight, Mirror and Window Switches
Golf VI Cruise Stalk
I-Pod Adapter in Armrest

Full Suspension Setup and Corner Weighting by Mick Gardner Racing

Cheers

Ry
 

NewTdi

Top Post Dawg
Joined
Jan 15, 2004
Location
NorCal
TDI
2003 Bora, Reflex Silver
just when I thought I did not want to do anything with my car ... here you are tempting me/us again! Good job!
 

Matt-98AHU

Loose Nut Behind the Wheel Vendor
Joined
Apr 23, 2006
Location
Gresham, OR
TDI
2001 Golf TDI, 2005 Passat wagon, 2004 Touareg V10.
Some day, I will have this engine... and install it into a Porsche 944 or some other good handling RWD car!

So Ryan, you going to start selling these engines as kits? :D
 

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 ........
just when I thought I did not want to do anything with my car ... here you are tempting me/us again! Good job!
Haha, Thanks!!!!

Just curious... what is your mpg now? After all that?
My bro has a stock BKD Golf that his GF uses and this returns MORE per tank with mixed driving, on a 70mph Motorway run it will average around 55-60mpg

So you had 235bhp with OEM-nozzles and big turbo setup ?!?!

Regards


Sent from my iPhone
Yes, it was smoke free too!

Some day, I will have this engine... and install it into a Porsche 944 or some other good handling RWD car!

So Ryan, you going to start selling these engines as kits? :D
Good condition engines are hard to find at the right price, I've sent out maybe 5-6 already, give it a couple of years and we will be sending conversion crates i'm sure!!
 

unclesfunnyonions

Veteran Member
Joined
Jun 17, 2008
Location
Barnsley,South Yorkshire, England
TDI
Golf GT 170
Hi Ryan, slightly off topic, but, how do you find the Rainsport tyres? I'm ready for a pair of fronts and i aint putting P Zero Neros on again, Too expensive and i haven't even got 10k miles out of them. :0

Whats the wear rate like on the uniroyals?

Alex :)
 

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 ........
They are around £100/corner and grip in the wet is no worse than in the dry really!!

I think the tyres have been on for over 8k of hard use + 20 runs up the strip and still have some life in them, I'd say in a normal setup they should last 20k, on the rear twice that!!
 

RudolfDiesel

Member
Joined
Aug 5, 2009
Location
Europe (A)
TDI
Das Auto
Yes, it was smoke free too!
:eek: ... AFAIK the stock BKD has 475 nozzles ... (-2004: PDE-P2/80/475S403)
To "flow" 235 bhp (is there maybe a factor between German hp an bhp ?! :confused:) out of stock 475 nozzles is in my opinion impossible ... but OK - i don't want to act as a wiseass ... it's only my opinion ... Why I am asking is:

A friend of mine has a BKD Audi A3 ... we installed BOSIO race nozzles (1287) and a special hybrid GT2056V turbo to get absolutely smokefree 450Nm and ~230hp ... 230hp on crankshaft !
230hp does not mark the absolutely flow-end of the BOSIOs - but I think that this is a good combination between "clean exhaust" and the durability of the turbocharger ... (at the moment he is driving with a 215hp mapping and 450Nm - ~2,2 bar maximum boost between 2500 - 3200 rpm, 1,95 bar @ 4000 rpm - but we are waiting for the last software-update to come :D ) ...

Regards
 
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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 ........
The car has been on 3 separate rolling roads, all with different method's of measurement/calcualation.

If someone can suggest a RR in the Uk (or anywhere if you pay!!) that will read what everyone says are 'True' figures i will take it there and video the dyno run!!!

The problem with German HP is just the numbers are always low :p Nothing about a conversion factor, ive never been impressed with any German tuner, even VW did a poor job, haha!
 

RudolfDiesel

Member
Joined
Aug 5, 2009
Location
Europe (A)
TDI
Das Auto
The problem with German HP is just the numbers are always low :p Nothing about a conversion factor, ive never been impressed with any German tuner, even VW did a poor job, haha!
:D:D:D

OK, i would say that it depends on laws of physics ... and not on German tuners :p

But we could compare ... if you want ?!

Do you have the possibility to weigh your car (as it always is) with a full tank of fuel and YOUR body weight (if YOU are driving) ?
Would be very interesting for me ...
The other thing is that I would need a log from your car ... measuring block 011 should be OK ... time(stamp) and rpm is important ...
You should log on an almost flat road - in both directions minimum 2 or 3 times WOT ("uphill/downhill") ... in 4th gear from 1200rpm - 4500 rpm ...

With this values we could make a comparison between the time/rpm passing of both cars ... depending on the vehicles weight ...

The gearboxtype (code) and the tire dimensions are also very important ...

Regards
 
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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 ........
The car weighs 1425 kg and i weigh roughly 75kg so lets say 1500kg all together, this is exactly how it would have been when i went to the 1/4 mile strip and did the 13.8.

I could get the logs for you when i have the car back :)
 

RudolfDiesel

Member
Joined
Aug 5, 2009
Location
Europe (A)
TDI
Das Auto
The car weighs 1425 kg and i weigh roughly 75kg so lets say 1500kg all together, this is exactly how it would have been when i went to the 1/4 mile strip and did the 13.8.

I could get the logs for you when i have the car back :)
OK - many thanks in advance !
Pls don't forget the gearbox-code and the tire dimensions ... ;)
Thanks !

Regards


Sent from my iPhone
 

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 ........
KXZ gearbox, 225/40/18, 30psi, 33" waist, 33" inside leg.......... haha
 

unclesfunnyonions

Veteran Member
Joined
Jun 17, 2008
Location
Barnsley,South Yorkshire, England
TDI
Golf GT 170
They are around £100/corner and grip in the wet is no worse than in the dry really!!

I think the tyres have been on for over 8k of hard use + 20 runs up the strip and still have some life in them, I'd say in a normal setup they should last 20k, on the rear twice that!!

Ta for that mate, just what i wanted to hear :)

I'll be in touch soon for TB, dpf/egr off etc. Just waiting on xmas bonus!!!!!

Alex. :)
 
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