Let the tinkering get serious!!....

[Transporter]

Go! Cogdoc,
Your set up will work just fine, but I'm worried about that tiny battery starting reliably the diesel engine.

[gldgti]

Polar certified mod. Plenty good enough for me.

Lots to do this weekend!

the fella's have a point - your 300CCA gel battery wont last nearly as long as the stock unit - BUT, it was probably cheaper

even old 1.5l mk1 diesels have 550CCA batteries, hehe.

BUT - really cant wait to hear how the meth injection setup goes! baited breath!

[Greg Roles]

Halfway through putting the Deka in, fabbing up the holder, but MAN, does it open up some serious space. I'll be able to put my Provent, Deka and a decent water meth tank in the same space as the giant stock battery, and there's no way I'm going back to it!

Like you suggest, if it's a bit low in CCA in real life, I'll put another smaller Deka in the boot quite easily given the size of my OO guage amp wiring. Too easy!

[Greg Roles]

This little battery starts the TDI in about a heartbeat. Right from the box too. I cranked it several times with the air con on, stereo system blaring, lights on, and it just kept on giving right out of the box. I have little concern at this stage, but will keep an eye on it. The sheer space it frees up is astounding, let alone the massive weight difference. I'm thinking the water meth tank , Provent and deka will all hide neatly in the VW battery cover too!

Still some tidying up to do, but look at all that space for more goodies!

[Greg Roles]

Put the Whiteline Anti lift kit and bushes in the front end Monday evening, and what a biarch of a job that is. I'd suggest anyone considering that upgrade get it done by a professional, it was about the limits of my home workshop / patience / number of swearwords.

The front lower control arm bushes are quite tight,, and you really need a press to get the old stock ones out. I had to get creative with the vice. Car feels far more solid in the front end, and once I get the rear bushes in I'll get a wheel alignment and report back, as I'm fairly confident that's out a bit now!

[gregozedobe]

Here's something for when you run out of things to do to your TDI (spotted at the Brickyard forum)

I went to the Autosport Racing car show on Saturday at the NEC Birmingham.

Was checking out a Corrado on Nitrous Oxide Supplies Ltd stand.
2.0 Tdi with Superchips remap and nitrous injection.
They were quoting 270 bhp with the giggle gas.

All it is, is a nozzle added that sprays N2O into the intake.
The ECU will recognise an increase in oxygen intake via the exhaust O2 sensor and will
send additional fuel to the injectors to supply the engine.
Instant 50 bhp increase - just don't get any greedier than that

[gldgti]

Put the Whiteline Anti lift kit and bushes in the front end Monday evening, and what a biarch of a job that is. I'd suggest anyone considering that upgrade get it done by a professional, it was about the limits of my home workshop / patience / number of swearwords.

The front lower control arm bushes are quite tight,, and you really need a press to get the old stock ones out. I had to get creative with the vice. Car feels far more solid in the front end, and once I get the rear bushes in I'll get a wheel alignment and report back, as I'm fairly confident that's out a bit now!

call yourself a serious tinkerer???? you need to get yourself a press! 2nd best bit of kit i ever bought i reckon!

good work btw - nothing like some good bushings to inspire confidence in the corners.

[Greg Roles]

The difference is amazing, even with the front alignment feeling out a bit, I get far better road feel through the wheel, and the slightest input has an immediate effect. The front does indeed feel far "sharper" as Polar reported. Hope to get the rear bushes in one night this week, and then get it aligned.

Investigated NOS at length Greggo, but the running costs are indeed big. I figure the Custom code and Meth should put me in that ball park anyhow.

[Greg Roles]

OK, put the whiteline trailing arm bushes in the rear this arvo, and it was a similarily challenging task. Has complimented the front nicely, in that on turning, the stock "rear" seemed to wallow out further, now it seems to follow the front much beter, and that "wallow" sideways feeling has largely gone. Still only on stock suspension, but despite the time and sheer agony to fit, a highly successful mod in my opinion.

Oh and wheel hop is still present, but seems quite a bit less to me on a test clutch drop tonight. Then again I haven't wheel hopped for over a year, ever since I learnt to use the clutch, so I may have forgotten what it's like in the stock setup.

My only other bush investigation is the top of the torque arm insert, I seem to recall it was possible to put the same bottom one into the top, to make it extra stiff, but need to research that one.

Time for an alignment!!

[gldgti]

ahh bushings.... always good value.

wheel hop - is this a feature of new "soft" cars then nowadays? i've never experienced it in the mk3, and only in 1 of my mk1's that had VERY worn out suspension and bushings.

must be the price of refinement i guess.... cos in the mk1 and mk3, theres not much of that by todays standards (though both my cars have low, hard suspension)

[Greg Roles]

Don't know mate, but I suspect so. Bottom line is a bit of a clutch slip and launching the diesel on boost makes for a MUCH quicker and smoother takeoff than just dropping it, but overall the bushings have made for a much tighter yet still comfortable drive. I'll go the suspension route in time, but need to recover from all this power up spending first...speaking of which...



This nice set of GTI intercooler hose upgrades arrived today, sadly I bought them from a middle man in Australia and only found them later direct on e-bay for about $80 less, but heck, what can you do? The biggest problem in upgrading the inlet is the couplings to the stock intercooler, swaged onto the stck rubber hoses, but this kit has some very nice alloy machined copies, lacking o-rings like the stock ones but as this is a potential point of leakage anyhow, I'll work on that.....the hose doesn't suit the TDI exactly, but it's sure close, and if the turbo coupling fits I'm going to be mighty stoked!







The hose is a LOT tougher and nicer than the spongy stock hose, if you're interested, zenaracing is your man!

[gldgti]

Hehe, blue... like mine.

I'm guessing from your pics that most of the pipe between the turbo and intercooler is that preformed aluminium one there? I think I get whats going on there

When you talk about leak points - are you saying that theres no external clamp on the intercooler inlet/outlets? I'd be interented to know reoughly the diamter of those joints too.

Looks to me (from your pic) like you could fit a larger silicone hose over the outside of the plastic intercooler inlet pipe, with a hoseclamp? Cant reeeally tell what that connection is like though.

In my experience so far, even a tridon hoseclamp will hold a 2.5" silicone hose onto a pipe under 25psi of boost without any leaks, just as long as theres enough anchorage (i use 8 big weld tacks around the outer edge of the pipe end) so that it wont completely blow off. But, looks a bit like there are circumferential ridges around that plastic end tank inlet pipe which could serve the same purpose....

[Greg Roles]

I take it back, these copy joiners even have an o-ring groove for the stock o-rings I'd assume, but I'll get some newies!

Not quite sure what you mean mate, but the plumbing is firstly that preformed ( deformed! ) alloy tune and roughly 2" at that point, rises to 2.5" pre intercooler, and is 2.5" all the way post IC ( except the massive bottleneck at the EGR ). I'll copy that to the letter, but with real tubing and quality silicon " hump" joiners. The fittings themselves are very specific, and a large C clip basically holds them in place, there's two teeth 180 degrees apart, and a corresponding window through which the clip holds the teeth.

I'll try and take a pic, but the basic problem is you really need these specific spun adaptors, even APR do one in their top end intercooler kit. Porsche have similar fittings apparently, and I've only heard they leak over at TDI club, so no real life experience there for me as yet.

When I'm done, mine won't leak!!

I'm at the stage of being ready for a mock up inlet, just need a clear weekend and I'm into it.

[Greg Roles]

Finally some real truth about Water Meth, and some real world numbers. Remember the article is on the MPG max kit, whereas I have the Stage 3 kit, so it's going to be a little better!

I posted a query about quenching and hydrolock up on the Snow forum, and here's the reply:

Hi Greg,

Our kits work very well on the TDI motors. Over-injecting will quench your motor well before any chance of hydorolock. It really comes down to nozzle selection to get the right ammount of fluid into the motor when you need it. For the TDI motor I would suggest using a 225 nozzle.

Diesel Power Magazine is featuring a 2009 Jetta TDI with our MPG-MAX system on it in their March 2010 issue . You can read the article here.

http://www.snowperformance.net/produ...e-file-135.pdf

Let me know if you have any more questions.

Thanks,

[gregozedobe]

Interesting article, and I'm sure one that has enthused you to get cracking with your kit

I would like to have seen the acual dyno curves, because max power figures at high revs are one thing, but it is interesting to see what changes have happened at low to mid revs where most daily drivers spend nearly all their time.

This isn't the first time a VW TDI has been measured as putting out significantly more power than VWs claim. IIRC most "125 Kw" GT TDIs that still have their original ECU mapping dyno test at around 135 Kw (at the wheels).