Enthusiast CJAA Build help/guidance

[S_Lafleur]

Alright, first-time poster here. I am usually hiding in the shadows, but I am seeking guidance on my build from those of you who know more than I. I am ultimately working to get ~300-400HP depending on the day that I am in research mode. I have always loved the idea of building something that most do not, that others think "isn't worth it" and even more to see the surprise on people's faces when I pull off the line. I absolutely love these TDI's! I do my own work and my own fabricating.


Here is where I am stuck...

I have been working closely with Malone to try and get optimized, but I have recently come into several stop points of my build. Irregular coolant temperatures spiking and holding to unsafe levels, WAY too high EGT’s and lastly my fuel delivery falling on its face over 3800RPM.

I was hoping some of you have had these issues and have insight on how you overcame them.

For the Cooling:

It runs normal temp until I push it a little then gets irregular. After testing my radiator isn't properly regulating and it is apparent on VCDS with the two sensors. When I did the recent build, I installed a new Thermostat assembly, but I feel it is still bad and have purchased another OEM housing to swap and try and correct this. More to come.

EGT temps:

I can’t figure out. I can only imagine is has to do with fuel delivery amount and is tied to the reason I am dropping in pressure at higher RPMs? Malone suggest I change to one of their exhaust manifolds in efforts of lowering EGT’s but there are people running 380HP with a manifold turbo like mine per PowerTDI so it is hard to believe that is the culprit especially with my port matching and flow porting I did.

Fuel delivery dropping:

I replaced my stock lift pump just in case it was the cause with a new OEM VW pump, no change. Could the CP3 be sucking the fuel lines closed and restricting the flow to the system? Again, I’m at a loss.

I was also told that my turbo may be at the top end of its ability so I am highly considering upgrading my turbo at least to the 350 range to match my stage 1 injectors to see if that would help but I'm not sure what that option looks like yet.

Thank you for reading my novel and I look forward to seeing what you guys think about my work and any input you guys may have!


Im unable to figure out how to attach pictures in this moment or I would throw a few on here to liven up the thread. Sorry



Build list below:

Current Setup

*Added since last phase of build/tune​

Tunes:

• Tunezilla Stage 4 Custom ECU Tune (V6 in process still):
  • 2200bar Rail Pressure Sensor
  • CP3 Tuning (CP3 Metering Valve: 0 928 400 643)
  • DPF, EGR, Swirl Deletes
  • Dynamic Idle 1100RPM

• Tunezilla Stage 4 TCU Tune (53192 – ST4_DSG_V3)
  • DSG Stage 4 custom

Engine:

• Darkside 12.9 tensile head studs installed
• *Honed cylinder bores
• *New piston rings
• *Hand ported and matched intake and exhaust head ports
• Darkside - Performance / Race Camshaft Kit for 1.6 & 2.0 TDI Common Rail Diesel Engines
• Oversized Inlet & Exhaust Valves (Stage 2): 8 x Stage 2 Inlet Valves = 29.2mm + 8 x Stage 1 Exhaust Valves = 26.7mm
• Darkside - Upgraded Valve Springs for 1.6 / 2.0 16v & 2.7 / 3.0 24v TDI Common Rail Engines (Seat pressure is 77lbs compared to stock 44Lbs, an increase of 75%)
• Piezo Injector Upgrade for Round Port 2.0 TDI CR Engines Stage 1 (350BHP)
• FCP Engineering H Beam Con Rods and ARP bolts for 1.9 PD130 / PD150 & 2.0 TDI PD / CR 140 / 170 (Shot peened and heat treated)
• ECS Catch can to atmosphere
  
  
  • ***Consider TDI Fluidamper kit Harmonic balancer or KermaTDI’s (not installed or bought yet)***

Turbo:

• GTD2060VR (powertdi.pl)
• Darkside - Turbo Blanket for VAG GTD2060VZ / GTD2263VZ / GTD2872VZ Turbochargers

Intake:

• K & N cold air intake + Custom pipework
• Darkside EGR delete blanking race pipe kit and full cooler delete (removed) installed
• Darkside full Swirl Flap delete kit installed

Intercooler:

• Comp. Gen.2 Intercooler Kit | wagner-tuning.com
• 4 bar MAP sensor 0281006059

Exhaust:

• Custom Full 3” downpipe to fit
• Custom made 3” Stainless 304 with Resonator Max Performance Kit
• 3” full 304 stainless downpipe to tip with a high flow resonator only
• Fiber wrapped custom downpipe

HPFP:

• Whitbread CP3 R70 High pressure fuel pump
• Cascade German 2200 bar CP3 rail sensor
• Aux fuel pump deleted

Chassis:

• Bilstein B4 shocks and struts
• Eibach ANTI-ROLL-KIT (Front & Rear) sway bars
• Front 26mm Rear 23mm
• ECS Dogbone mount Billet
• IRS Swapped
• New rear hubs
• Added Traction Control disable feature
• New front hubs
• New ball joints
• Eibach pro kit springs front and rear
• ECS Flush wheel spacers
• New CV Axles

Brakes:

• Rear power stop Z26 performance rotor and pad brakes
• Front power stop Z26 performance rotor and pad brakes

• ***Consider upgraded calipers***

 

[CanadianALH]

@lemoncurd and @Xtremefunky will have some answers for you. But you should be able to get those EGT’s under control it’s probably over fuelled and that’s causing those EGT’s. How smoky are you right now

 

[S_Lafleur]

@lemoncurd and @Xtremefunky will have some answers for you. But you should be able to get those EGT’s under control it’s probably over fuelled and that’s causing those EGT’s. How smoky are you right now

Not rolling coal but definately pushing some dark smoke. Once i get my coolant under control i can do a few pulls and post

I have a gut feeling my turbo needs to be bigger for this current build

 

[lemoncurd]

your issue with EGT and fuel is entirely with malone. seriously.

@Xtremefunky can tune the car, and has better results.

i used to run malone stage 4 on my gtb2266, they seriously could not get it right.


as far as upgrading your turbo, yeah youll probably need a bigger one to hit 400. buy a GTE2260 from muchboost.

ps; it's hilarious they suggest using their manifold. I HAVE IT and their EGT's were still sky high LMAO

 

[WWJSWD]

• ECS Catch can to atmosphere
  • ***Consider TDI Fluidamper kit Harmonic balancer or KermaTDI’s (not installed or bought yet)**

Go with Whitebread performance for the Fluid Damper, also get their lower timing cover. There's a gap in the OEM lower cover that allows for the serpentine belt (if it were to shred) to be pulled in and wreck the timing belt. I have both, I've noticed a significant reduction in vibration, and happy to have some peace of mind when it comes to the belt issue.
(Fluid Damper)

TDI Fluidampr

This is a 1.8T Fluidmapr that has the necessary machine work performed by WPI to make the serpentine belt alignment correct for ALH, BEW, BRM, or common rail tdi's.

whitbreadperformance.com

(Lower Timing Cover)

Common Rail TDI Lower Timing Belt Cover

After multiple customer requests and seeing a handful of shredded serpentine belts get sucked into the timing belt, we felt a solution was necessary for the CBEA/CJAA motors. CNC machined in house from 6061 aluminum, these fit much tighter around the harmonic balancer to effectively eliminate...

whitbreadperformance.com

As everyone else has mentione, EGT issue is related to the tune 100%. Check out https://www.youtube.com/@scoptimizations to get an idea of the amazing work @Xtremefunky and his team can do.

 

[S_Lafleur]

I have been throwing around getting both of those for quite some time. Thank you! Ordered now.

I've also purchased a GTD2265vklr to upgrade my GTD2060VR. I think this turbo will fit best with this build from what I am hearing and reading from everyone here.

It super sucks that they can't figure it out... Since the custom tune fee has been paid, I am going to give them another few shots after I install the new turbo, coolant thermostat, harmonic balancer and guard. I must get my engine coolant reacting normal before too much heating up and pulls... I REAAALY hope it was just a bunk thermostat because I'm at a loss for what else it could be.

If they can't get it with all hardware mods done. then naturally I will absolutely be reaching out to Xtremefunky.

 

[CanadianALH]

I have been throwing around getting both of those for quite some time. Thank you! Ordered now.

I've also purchased a GTD2265vklr to upgrade my GTD2060VR. I think this turbo will fit best with this build from what I am hearing and reading from everyone here.

It super sucks that they can't figure it out... Since the custom tune fee has been paid, I am going to give them another few shots after I install the new turbo, coolant thermostat, harmonic balancer and guard. I must get my engine coolant reacting normal before too much heating up and pulls... I REAAALY hope it was just a bunk thermostat because I'm at a loss for what else it could be.

If they can't get it with all hardware mods done. then naturally I will absolutely be reaching out to Xtremefunky.

I got a refund on my Malone tune. I think you could probably too. That was a good thing is their customer support was pretty good

 

[S_Lafleur]

Question... random thought. When i wired my plug for the CP3 i assume i was careful to match the wires but if maybe i switched them do we think that could be a potential cause of the fuel drop i see?

 

[dieselherb1]

I have Malone tune also. Having issues with ECM cutting fuel at 4000 rpm.

 

[Xtremefunky]

probably over fuelled and that’s causing those EGT’s. How smoky are you right now

since we have cylinder pressure sensors on the Ecu and I know how Malone „tune“ and the others. The Ecu basically freaks out seeing a huge deviance between requested engine torque and measured engine torque. This on the other hand effects the timing of the fielling

youll probably need a bigger one to hit 400

I HAVE IT and their EGT's were still sky high LMAO

well. They say it helps. They just forgot they meant their own pockets.

EGT issue is related to the tune 100%. Check out https://www.youtube.com/@scoptimizations to get an idea of the amazing work @Xtremefunky and his team can do.

thank you and all for the flowers

I think this turbo will fit best with this build from what I am hearing and reading from everyone here

with your camshaft this turbo may work better. It depends a bit on the inducer style of the turbo (VZ vs VRK) and the used compressor wheel.
Most of the available 6+6 65mm combined with a very narrow inlet, will have surge on the 2.0TDIs (without anti surge).
My personal suggestion is the GTE2260. This turbo makes basically everything better than the GTD. (Technical Evolution and so) Where on the other hand, it only has a disadvantage of maybe 30-35HP compared to a GTD2265. But this is only peak in lower gears (where you can’t put the power fown anyway). Once the EGT regulation sets in, the GTE will pull away.

 

[S_Lafleur]

I was able to finish my new thermostat installation and test a bit today. The heater is still sporadically blowing cold and hot, fans don't kick on when they should to cool but they DO come on when i click over the AC button... Next step is verifying the Heater core is clear (i have no reason to believe there is a blockage...) and then im guessing i replace the Water pump that only has 900 miles on it because maybe the turbine is hosed?? lol this is dumb.

 

[S_Lafleur]

Go with Whitebread performance for the Fluid Damper, also get their lower timing cover. There's a gap in the OEM lower cover that allows for the serpentine belt (if it were to shred) to be pulled in and wreck the timing belt. I have both, I've noticed a significant reduction in vibration, and happy to have some peace of mind when it comes to the belt issue.
(Fluid Damper)

TDI Fluidampr

This is a 1.8T Fluidmapr that has the necessary machine work performed by WPI to make the serpentine belt alignment correct for ALH, BEW, BRM, or common rail tdi's.

whitbreadperformance.com

(Lower Timing Cover)

Common Rail TDI Lower Timing Belt Cover

After multiple customer requests and seeing a handful of shredded serpentine belts get sucked into the timing belt, we felt a solution was necessary for the CBEA/CJAA motors. CNC machined in house from 6061 aluminum, these fit much tighter around the harmonic balancer to effectively eliminate...

whitbreadperformance.com

As everyone else has mentione, EGT issue is related to the tune 100%. Check out https://www.youtube.com/@scoptimizations to get an idea of the amazing work @Xtremefunky and his team can do.

Installed today, Cant wait to drive with it on now! thanks again for the recommendation

 

[S_Lafleur]

@lemoncurd and @Xtremefunky will have some answers for you. But you should be able to get those EGT’s under control it’s probably over fuelled and that’s causing those EGT’s. How smoky are you right now

It is very smokey.... Malone is overfuelling and that is why my EGT's are hosed and my fuel is dropping off...?

 

[lemoncurd]

It is very smokey.... Malone is overfuelling and that is why my EGT's are hosed and my fuel is dropping off...?

overfueling which leads to smoke, and they also ham fist the injection timing/duration tables which hurts EGT alot.
they "make up" for this by simply deleting the EGT limiter