The 1998 B5 Passat TDI (one of 2 stateside?)

[rotarykid]

fyi your dhl is 2.66 final drive 5th. Try to get a dqs-2.15 final drive in 6th if your insistent on a 6sp. Frans has them from time to time for arround $2500. I got a european tdi fhn 5 sp-2.36 from him. Sweet ride YA GOT THERE!

If you go that high you will really need to watch the EGT's, I have taken things about high as they can be taken by installing larger diameter tires on a 1Z Passats. EGT's climb through the roof pretty quick under heavy loads at speed with gearing that tall.

Monitoring oil temps along with the adding of extra oil cooling is also a good idea if you are going install taller gearing.

Something else I have found that helps with EGT spikes is the adding of a water jet in front of the inter-cooler. A windshield washer bottle and motor works very well for this, junk yards are full of options that will work. Regular water in summer and washer fluid during colder months.......

 

[JFettig]

Bigger turbo does the job too

I have a line on a trans already, not sure what ratios they are(they are tdi ratios) but I don't like tractoring around anyway.

 

[50harleyrider]

The 1Z(sure looks like one) really responds well to stage 2 and PP520s with a stock turbo. I ran a .622 fifth in mine and it had a big drop in 5th. With the extra gear, not a problem- a DQS should do you fine and no tractor! I would check the code on the one you have lined up at any rate. Some 6 sp have a short 6th ratio and you don't want that for your expensive tranny. I believe only 6sp gassers were imported that will fit your B5, so make sure you are indeed getting a European TDI 6 sp. I've gathered some extensive gearing charts so you can PM me the code. I love your car!

 

[bhtooefr]

This is an AHH, which is best thought of as an AHU with an ALH turbo, 11 mm pump, and I believe the same injectors as an automatic ALH, too.

 

[G60ING]

This is an AHH, which is best thought of as an AHU with an ALH turbo, 11 mm pump, and I believe the same injectors as an automatic ALH, too.

Yes the injectors are the same as an automatic ALH. I had a set of AHH injectors.

 

[JFettig]

 

[JFettig]

Calculated RPM and torque

234whp, 373ft-lbs

Wasn't even hitting target boost, should be able to make 400ft-lbs
Almost smoke free

AHH with stock 11mm IP
PD Lift pump
Rosten H-beam rods
ASZ 18.5:1 PD pistons
R520 nozzles set to 230/340 bar
Stage 2 Colt cam
Ported head
GTB2056VL on a ported 1.6 TD manifold with adapter plate
2.5" exhaust, 2 resonators
SBC Stage 2 endurance clutch
Upgraded head bolts and main bolts
EVOMS FMIC
Custom boost piping
Custom intake.
4bar map


That should be everything.

 

[greengeeker]

So what are you running for fueling? 11mm, lift pump?, Warp 10,000,000? nozzles?

Nice numbers!

 

[JFettig]

11mm, lift pump, R520, not maxed out yet

 

[greengeeker]

What? You're not using Warp nozzles? I heard they were the shiznit...

 

[JFettig]

They're hit and miss in the larger sizes.

 

[leon10tagg]

Nice figures.....I bet it runs real nice on the road......

 

[JFettig]

Can anyone guess whats going on here?

 

[Digital Corpus]

Which ECU are you going to be putting in?

 

[G60ING]

Removal of the TDI and installing a VRT?

 

[JFettig]

no way, keeping the TDI! A VR5T would be fun

I'm doing an EDC15 swap. Its a 2003 golf harness. I don't have a 2003 ECU but I'm hoping to find one. I have a 2001 ECU, so we'll see if does the job - 1 pin for the glow plugs is different and its a completely different glow plug system, luckily I don't really need them in this weather!

 

[1854sailor]

Will we see this car at TDI Fest??

 

[JFettig]

Yes, unless I break it

 

[compu_85]

I'm doing an EDC15 swap. Its a 2003 golf harness.

At this point why not mod some other B5 Passat

-J

 

[JFettig]

At this point that would be way too cost prohibitive.

 

[TDIJetta99]

At this point why not mod some other B5 Passat
-J

That would mean he'd have to buy another B5 passat and source a TDI drivetrain for it... MUCH more expensive than doing a harness/ecu swap for something a little more tuner-friendly..

 

[JFettig]

Making progress

 

[JFettig]

mmm obd flashing from the drivers seat, I don't even have to get up

 

[JFettig]

I was able to convert my ECU from a 012BD to 012FD

Now only one code to remove - MAF, no longer present. No other codes!

 

[TDIJetta99]

That's pretty sweet..

 

[Digital Corpus]

Congrats on the swap

 

[greengeeker]

Man your harness must have been a lot cleaner than mine. No way I could have done my wiring on my living room floor. Nice work on the swap.

 

[JFettig]

Couple cans of brake cleaner did a good job cleaning it!

Brake cleaner kills the adhesive in the friction tape, removed all that, then cleaned all the remaining goo off it with more brake cleaner.

 

[JFettig]

damn, couple key cycles and I got an eeprom error

Finally a smoke limiter! Its 98% smoke free, quick mods and it should be 99.5%

I overlaid the last log I took on my old ecu and its just as quick, spools a hair later but that can be fixed with the smoke limiter mods since there is no smoke at all on spool up.

I'll have to see what happens when I go back to BD software, move the glow plug monitoring pin over to the proper location, hopefully its ok with the 2003 relay.

 

[JFettig]

Harness is 99% complete, just a couple more sensors to add to it for my DAQ and get more friction tape.

For the DAQ I have:
Boost
IAT
EMP
EGT
OIL P
WBO2
RPM