Let the tinkering get serious!!....

[Preen59]

Nice work, Greg.

I've been tempted to buy one of those boost referenced snow kits, but haven't worried about it just yet. Would rather get the other money pit going.

I'm extremely interested to see how your kit goes.

[Greg Roles]

OK, electroncs are all but hooked up, much neater, and I'm down to fine tuning this weekend. Onto the inlet now, and my Pa has lathed up the QTP, so the next phase is the inlet plumbing. I'll be sure to do a before and after dyno run on the stock ECU with the snow gear so we can see how it performs.

On that note I've just chatted tonight with the third person who is interested in going the DPF delete and water meth route, and I'd just like to say that there's NO WAY I'd be doing that on a DSG, and adding meth over the top of an already massive tune without a lot of monitoring, safety, heat etc mods, well I'd not be putting any cash on your engine / trans longevity. Remember the 2.0 TDI has a massive torque spike at 2000rpm, and it's THAT which is the problem, not the final NM handling fgure. I'm worried people will just take the power adding ideas I've listed without any of the cooling, monitoring and safety mods I've done, and there's a lot more than I've been bothered to list on my threads. An EGT gauge is the bare, bare minimum!!

Think it through people, the stock tune is showing dangerous temp spikes, water meth at 50/50 is still only "neutral", meth adds heat, water drops it. Hence all my other work to allow for that!

In the end it's your call, but I'm worried with the plans people have out there!

[h100vw]

Maybe 20% meth would be a safer mixture to inject Greg, at least it would pull some heat out. That top Snow kit has EGT monitoring doesn't it? Agreed it all needs logging to make sure it's doing it's job. That could be time consuming job, having read that thread I sent you.

Gavin

[Buller_Scott]

In the end it's your call, but I'm worried with the plans people have out there!

awww damn because i was gonna run a chip express plug in module on top of my track map, like some guys are doing with their GM diesels.....

lol j/k.

this thread is inspirational. you've got mega balls and A LOT of gumption. rad work, greg. most rad.

[ml16]

This is awesome mate, a great read.

Be interesting to see how the DPF and tune go. I am looking to do just a cat-back and CAI with a tune to mine and then focus on handling.

You are a diesel pioneer!

[Greg Roles]

Thanks for the kind words. Does feel a bit lonely modding a euro diesel in Australia!

Anyhow, we have green across the board.....electronics cleaned up and virtually complete ( that was a days work in itself! )....and my extra MX radiator for the oil cooler is mounted. Unsure if this last idea will actually do anything at all, but heck it makes me feel all warm and fuzzy.







Off to play with the turbo timer......

[Gregski]

looks great mate, love the oil cooler mounting

all very tight and neat

now get that freakin DPF on so i can see the results!

[Greg Roles]

Been quietly tinkering away on these cold winter weekends, bit of bling, and a bit more poke. Did one centre console garnish in real carbon, and what a biarch that was, peeled it off, and what you see below is vinyl. it looks amazing!

Airbox to turbo is now full 3" tube, and the maf is bolted through a hole in this tube, so I'll see today if it still runs OK. The reason there's so much red is that I put an extra connector over the tube to help insulate it from the hot fuel pump to the left.

Almost ready to do the same on the IC plumbing. Happy days!

[POLARBEAR666]

Hey Cog, how much difference has the diff made to your 0-100 and feel of the car? is it vastly improved with the mechanical lsd?

[GoLfMan]

have you considered an Allard tuning EGR delete pipe mate?

[Greg Roles]

Polar: I want to get a Peloquin mate, but haven't bought one as yet!

Golfie: Making my own, but Allards doesn't defeat the main problem, that is the Lamda sensor in the exhaust will be looking for EGR operation and throw errors if you just blank it off. You could go an allards and a wayne angle block off Vortex, which is my interim solution till I can defeat the ECU properly, as tuners in the UK are starting to offer.

[GoLfMan]

ahhh very interesting.

I'll be doing that and a FMIC at the same time

[Greg Roles]

I'm following the pipework as per VW, but of course without the restrictions, spongey rubber hose, dodgey couplings and mashed turbo outlet pipe. The "hot" side of the IC plumbing goes from around 2" to 2.5" stock, so I'm doing the same, and it's a full 2.5" on the "cold" IC outlet side. Obviously the greatest restriction in my mind is the "throttle" flap for the EGR valve, at a nasty square edged 1.9". That's gotta go!

Defeating the EGR valve itself looks do-able, but the flap, well that's gonna be tricky. I'll use the wayne angle block for now to trick the lambda probe into thinking theres plenty of EGR happening, and work on an electronic defeat. Sadly for now, I figure I'm going to have to leave the mechanisms plugged in and zip tied out of the way so the car doesn't throw error codes, but I'll be working hard to get rid of that eyesore! Preeny, time to hit the post office ol mate.....

Off to the left are my spares, that I'll flog off once it's completed. It's all 2 - 2.5" mainly.

[Buller_Scott]

sweet. lookin good, cog!

btw your engine bay is frigging sweet, now that i sorta know what im looking at.

p.s. the egr flap, when throttle is increased, it closes off so that air flow from the post-intercooler pipe is DEcreased, and more exhaust gas flows through into the manifold, yeah?

or is that scotty-made-me-facepalm type talk again? lol.

[Greg Roles]

Pretty much mate, the flap runs according to various parameters, and is designed to create a vaccuum at the egr valve so it sucks in exhaust gas. I'd reckon it happens mainly on decel and coasting / normal driving, and opens up lowering EGR nder accel, but I'm only guessing.

Bottom line it causes restriction, so it's gotta go.

Thanks for the engine bay comments, I want to carbon skin the tappet cover and manifold yet, but it's a complex task, so we'll see. Will look much better once all the EGR stuff is gone!

BTW the new inlet really makes the turbo sound like it's really "up in the dash" now, not obtrusive, but I really like the difference. Before you could hear POD induction noise, now it sounds more turbo suction and "closer". Car seems extra responsive, but I'm sure it's placebo / colder weather. Running a treat with the home made maf pipe too!