wild03 said:
If the turbo vanes fully open at 3K, I probably do that 3 or 4 times on the 16 mile drive. What I understand about taking it to 4K is that it will accelerate break-in. I'm not too concerned about this one, I rather just exercise the turbo vanes a few times per day.
I understand about the higher speeds, I'm more concerned about the extra fuel of reving the engine that high and cycling the Rpms in such un-natural way.
Again in the vanes fully open by 3K, I'll do that a few times a day.
To solve your immediate issue, slightly above max torque ( 1,750-2,250 rpms) say 2,300 to 2,500 rpms, the turbo is on boost AND the turbos vanes are doing their VARIABLE (pilates) gig .

The other issue is with the redline being at 5100 rpms again 75% of that is 3,825 rpms (aka 4k for government work) 75% is WELL below punishing !!??
It was very obvious the "fuel issue" is of issue to you. What I/others are trying to get you to see is by concentrating on the fuel issue "exclusively" you are "increasing the chances" (clearly no guarentee!) of mechanical issues down stream as drivng the TDI can be very "fluid" and for sure cummulative, so to speak. You also oxymoronically increase the chances getting LESS fuel mileage (as Drivibiwire illustrates using his own experiences breaking in a new 09 MB SUV).) Drivibiwire has posted before on the "topographical" curve of the TDI's fuel efficiency map. You might want to search for it or if it has changed much, Drivibiwire might up date it.
This might be off topic, but since you seem to come to the TDI by way of the/your gasser (NON TURBO I presume) experience, let me use a Honda Civic analogy. Again it is the same issue. Know and understand the parameters of your machine (Civic in this case) . We use it in a point a to point b daily commute and I assure you, we drive the TDI and Civic FAR differently. Come to this is the EXACT point A to Point b distance and (circus here) 3 drivers. Rather than bore you, fire away. Or tell me what you would do to achieve (exceed) those numbers.
But here are the mpg numbers: 03 TDI Jetta range 48-52 mpg, 04 Civic 38-42 mpg. If you are using a 09 TDI, it does a range of 39-45 mpg with 42.5 to 43 mpg as an average. This car is still in perpetual break in mode @ less than 9,000 miles.
If you look at Civic surveys we are in the top 3 to 6% of mpg and don't even TRY !!!!!??? In other words 97% to 94 % of Civic drivers report WORSE fuel mileage. We routinely rev it to 75% of redline (4575/6100 rpms max hp), coincidently max torque is rated @ 4500 rpms!!!!, counter point: baby it. We change oil and filter every 20,000 miles, counter point: 5,000 miles OCI is about MAX.