VW Jetta 2.0 16v TDI (BKD) - 301hp & 440Ft/Lbs GTB2260Vk, Tubular Manifold, Race PDs

[ryanp]

Here are some pics of it when I got it:







First up is the chassis -

Audi 18" x 8.5" Fat Fives with 225/40/18 Uniroyal Rainsports



KW V1 Inoxline


We also fitted an Audi TT 2.0 TFSI Rear Axle and Alloy Hubs that gave us 26mm more width and TT Front Alloy Hubs and Cast Wishbones, which give an extra 30mm and more camber. I have loads of pics, but didn't upload them. Everything is much beefier and lighter.

R32 345mm Front and 310mm Rear Discs. The front calipers have a TyrolSport Caliper Stiffening kit, which I would recommend it to anyone. Google it and see what I mean.

[ryanp]

We used Eos 3.2 FWD Splash Guards with fit perfectly with a slight modification


And it looked like this:





We then fitted a Darkside Developments EGR Delete and removed the EGR cooler completely:

After we mapped it and took it to the dyno, here were the results:


Some little interior mods -

Scirocco Flat Bottom MFSW



Passatt CC Switches


Thats how it stayed for a few weeks, but we had plenty more in the pipeline.

[ryanp]

We then concentrated on the body mods, we did the following:

Golf GTi Front bumper with Summer grills
Jetta GLI Rear Valance
Hella Projectors with Lamin-X Gun Smoke Tint and Osram Nightbreaker Bulbs
Smoked Rear Lights
Smoked Reflectors
Smoked Indicator Lenses
Smoked Numberplates
Rolled and Flared arches
Black VW Emblems

Here is how it looked:





Next was to fit the Darkside Developments 2.0 16v TDI Turbo kit with a GTB2260VK Turbo from a 3.0 v6 Audi:


Along with an S3 Intercooler and hard pipe kit (I didn't get a pic of the cooler before we fitted it, but it is all alloy with welded end tanks and no clip connectors):


Milltek 3" System (made for a US Jetta GLI):




We also modified the MAF, as it was deleted from the map:


Then we took it to the same dyno so see what we were making


235.3BHP and 330Ft/Lbs. This is on a very conservative dyno (the operator calls it the 'heartbreaker') with ZERO smoke and a very road friendly tune. 3 days after fitting the turbo I drove 1500 miles to, from and around Cornwall and averaged 57mpg for the whole trip. It didn't skip a beat.
We still have some adjustment in the stop screw to get the boost to come in a little earlier, but it still pulls very well from low RPMs. What you lose at the bottom end is nothing compared to what you gain at the top end, it pulls like crazy to the 5000rpm fuel cut we have in the tune and pulls 130mph in 5th easily. I have found the 140mph electronic limit though, which we are working on removing ASAP!

[ryanp]

Next on the agenda are a Sachs SRE Single Mass Flywheel and Sintered Paddle Clutch, Peloquin Limited Slip Differential, fitted to a low mileage PD170 Long Ratio Gearbox




Someone on the Edition 38 forum posted up a pic of the Jetta at their show:



We then fitted the Sachs SRE Single Mass Flywheel and Clutch and a PD170 Long Ratio Gearbox with a Peloquin LSD Installed. We also strengthened the shifter forks so we can do some fast changes. Once the clutch was run in, a set of Race PD Injectors was dropped in.

Here are the results from this afternoon:



We did 3 pulls and they were all pretty close together, the best run was 301hp and 440Ft/Lbs.



And here is a graph comparing the stock power to now, we have made pretty good progress!



Here is the spec we have now:

2.0 16v BKD PD140 Engine
Darkside GTB2260Vk Turbo Kit with Tubular Manifold and 3" Downpipe
Darkside Race PD Injectors
Darkside FMIC Kit with S3 Intercooler and Alloy Pipework
Darkside EGR Delete Race Pipe (Retaining ASV)
Milltek 3" Non-Resonated Exhaust System with Twin 76mm Jet Silencer
Darkside Developments Re-Map with MAF and EGR Delete

301BHP & 440Ft/Lbs – Dyno Proven

PD170 BMN Long Ratio Gearbox
Peloquin Limited Slip Differential
Sachs SRE Single Mass Flywheel with Sintered Paddle Clutch
Polyurethane Filled Dog Bone Bushes
Darkside Developments Short Shift and PU Filled End Links

R32 Front Brake Calipers
R32 345mm x 32mm Brake Discs
Genuine Audi S4 Front Pads
TyrolSport Caliper Stiffening kit
R32 Rear Calipers
R32 310mm x 20mm Rear Brake Disc
Genuine VW Rear Pads
Eos 3.2 FWD Rear Splash Guards
Silver Zinc Plated Calipers

KW V1 Inox Coilovers
Audi TT Front and Rear Top Mounts
Audi TT Alloy Front Wishbones with Solid Bushes and Adjustable Ball Joints
Audi TT Alloy Front Hubs and Alloy Track Rods (26mm Wider Track)
Subframe Spacer Kit
Audi TT Driveshafts
19mm Front ARB
Audi TT Rear Axle with Alloy hubs (30mm Wider Track)
Passat R36 21.7mmx3.6mm Rear Anti-Roll bar

Audi A8 ‘Fat 5’ 18”x8.5” ET45 Wheels
Uniroyal Rainsport 2 225/40/18 Tyres
Genuine VAG Wheel Bolt Caps
18" Spacesaver Spare

Hella Projectors with Lamin-X Gun Smoke Tint and Osram Nightbreaker Bulbs
Smoked Rear Lights
Smoked Reflectors
Jetta GLI Rear Valance
Rolled and Flared arches
Black VW Emblems

Leather Sports Seats
Scirocco R / Golf IV Multifunction Steering Wheel
Scirocco Headlight, Mirror and Window Switches
I-Pod Adapter in Armrest

Next step is a cam, headwork and bigger injectors. All of which are difficult to source, but I will find them!

Any questions, please don't hesitate to ask!

Thanks

Ry

[Mk3 AAA]

Waaaah, very nice. Great work!

[Smead]

Very Nice! That thing sounds like a weapon

[GoLfMan]

holy jesus. 600nm at the front treads! That thing must be a handful!

Nice work

got a in car video of it yet?

p.s some of your photos didn't work

[ryanp]

Thanks Guys, Videos will follow shortly!

Which pictures dont work? they are all hosted on the same server so in theory it would be all or none!! haha

[GoLfMan]

my computer obviously had a hissy fit. All there now! Nice Dyno graphs!

[Silver dub]

Loving the wheels on this!

[AlexRO]

wow this is crazy ! needs videos now

[dylan8]

wow. something to get the aussie jetta drivers going.
Love the wheels also!!

[team_v]

Looks great and love the work you have gone through with it.

Just wondring if there is anything you can do to hold peak power longer?

[ryanp]

Why, do you need more than 300hp past the 5200rpm limiter? haha! if you mean the torque then we can hold it longer with a ported head as that is the restriction now but reprofiled cams might actually give decent gains so we will go down that route first! If we can do 320hp on an unopened engine i'll be happy.

[team_v]

Why, do you need more than 300hp past the 5200rpm limiter? haha! if you mean the torque then we can hold it longer with a ported head as that is the restriction now but reprofiled cams might actually give decent gains so we will go down that route first! If we can do 320hp on an unopened engine i'll be happy.

forgot it was a diesel, hence the lower redline point.