Author Topic: TDI performance mods with the best value/bang for the buck (Read 8657 times)

tripod · « **on:** February 14, 2009, 12:42:07 pm »

Hi,
I am new on this forum and would like to soak in all the info that any well informed member would like to share. I am still learning alot of the terminology, so I will not be insulted if you dumb it down for me, in fact I would prefer it.

Anyways, I have a 2001 TDI from a Jetta that I will be swapping into my 88 Suzuki Samurai. I plan on converting to a M-TDI. What are the recommended turbos for this pump, as I understand that the turbo on my TDI is electronically controlled and will need to be replaced with the M-TDI swap.

Also, I will be rebuilding the engine with the help of my gf's dad, who is a diesel mechanic. While Im in there I would like to do any modifications that will in order of importance: 1. Increase durability/reliability 2. increase efficiency (which I'm hoping will equal improved mpg's) 3. increase hp/torque across the whole powerband.

So which mods are so beneficial and reasonably priced that I can't afford to not do?

Thanks for the help in advance.

dillenger1 · « **Reply #1 on:** February 14, 2009, 04:40:02 pm »

search option?It all depends what youy want.You can just do nozzles for some nice power and it would be least expensive,which would be stage 1.then you get into chipping +nozzles stg 2.then chip,nozzles,turbo,cam,nitrous stg3-4

the caveman · « **Reply #2 on:** February 15, 2009, 08:45:23 am »

I had my 98 ecu chipped and then installed bigger nozzles. regular cost would have been $500 cnd, but a got a deal. Took 1 1/2 hr s to do it all and then pressed the throttle and hung on while smelling my clutch and tires fried. If you were gonna keep the ecu it have to be flashed rather than chipped .

jimfoo · « **Reply #3 on:** February 16, 2009, 05:29:01 am »

Ummm, how is chipping going to help an M-TDI? He isn't going to have any electronics.
Nozzles, IC, adapt your VNT to run off boost. See mine, Tintin's or Libbybapa's threads to see how to do this. 1 note however, I have had problems with my VNT, but I think it is just mine that is the issue.

the caveman · « **Reply #4 on:** February 16, 2009, 07:02:49 am »

"mmm, how is chipping going to help an M-TDI? He isn't going to have any electronics. "

Well that's because as usual, i shot my mouth off before thinking, It's what my girlfriend and parole officer keep saying at least. :oops:

bluemotion · « **Reply #5 on:** March 03, 2009, 07:38:26 pm »

Go with larger nozzles. .216 nozzles should be good on an M-TDI. Most M-TDI pumps are custom jobs, so have it made with an 11 or 12mm rotor. Assuming you are dumping the VNT turbo, go with the 1z/AHU exhaust manifold, K04 turbo and downpipe. Then think about a larger intercooler.

tripod · « **Reply #6 on:** March 06, 2009, 01:02:21 am »

thanks for the responses all!

Bigger nozzles will definately be one of my first mods. The donor car is an auto, so it has the 11mm injection pump and small nozzles.

I am also having second thoughts about going m-tdi. Initially I was under the impression that the injection pump was going bad, that's why I wanted a m-tdi. But I'm getting alot of pressure to my nozzles when I loosen them while its running. There are alot of air bubbles in the visible line after the fuel filter, so I have to replace that and see if that stops the surging that is happening.

Freidenker · « **Reply #7 on:** March 11, 2009, 05:36:00 pm »

Rebuid the 11 mm pump, have the bore checked and rebore if necessary, fresh bearings, gaskets, etc. and a good tune reflash. Best thing to do is contact a tuner you like and see what they say about turbos. Some require a bigger turbo with nozzles. Rocket chip has staged tunes that take you into the realm of turbo upgrades. Ask them about reliability issues with increased power and figure out how much risk you want to take. That's what I'd do, personally.

subsonic · « **Reply #8 on:** March 11, 2009, 07:35:56 pm »

I think we need to consider what this engine is going into, and what it's usage will be like. Will this be a strictly off road vehicle or a daily with some off road. What are you going to run for tires and axles, stock, 33"s or 36"? If you are going to go rock crawling you need lots of low end, mudding needs rpm's. You gonna run a winch? Need a bigger alt? Etc, etc. You planning on taking this through water crossings? All this makes a big difference in how you set up your engine.

Freidenker · « **Reply #9 on:** March 12, 2009, 04:14:05 am »

Are you going to use one of the available swap kits for the Samurai?

tripod · « **Reply #10 on:** March 26, 2009, 09:56:50 pm »

Quote from: "Freidenker"

Are you going to use one of the available swap kits for the Samurai?

Yeah, I will be purchasing an Acme Adaptors kit, which will mate the engine to a Toyota 5 speed manual. I will need to fab my own motor mounts and tranny crossmembers.

This brings up another concern. Does the ECU have any sensors in the tranny? Since I will be running a Toy 5 speed, which is a much more simple tranny than the VW trannies offered, will the ECU allow this setup to function and if not, can I delete a code to make the Toy 5 speed work?

tripod · « **Reply #11 on:** March 26, 2009, 10:19:48 pm »

Quote from: "subsonic"

I think we need to consider what this engine is going into, and what it's usage will be like. Will this be a strictly off road vehicle or a daily with some off road. What are you going to run for tires and axles, stock, 33"s or 36"? If you are going to go rock crawling you need lots of low end, mudding needs rpm's. You gonna run a winch? Need a bigger alt? Etc, etc. You planning on taking this through water crossings? All this makes a big difference in how you set up your engine.

This vehicle will basically be my daily driver, so road performance will be of importance. I will be running a SPOA with YJ leaf springs. I eventually will have Toyota axles w/lockers. I have 31" BFG mud terrains but plan on running 35"s in the future. I will offraod a few times a month, mostly trails and mud. I live in Hawaii, so the rock crawling is scarce. There are a few places that I wheel that have seasonal water crossings, although Im not sure how deep a water crossing I will want to take it through since these motors are pricey. I may have a winch one day, but it is not a must have for me but I will probably run a dual battery setup so I do want a capable alternator.

Anyone know how much amps the VW alternator on my 01 puts out?

tripod · « **Reply #12 on:** March 26, 2009, 10:36:23 pm »

Quote from: "Freidenker"

Rebuid the 11 mm pump, have the bore checked and rebore if necessary, fresh bearings, gaskets, etc. and a good tune reflash. Best thing to do is contact a tuner you like and see what they say about turbos. Some require a bigger turbo with nozzles. Rocket chip has staged tunes that take you into the realm of turbo upgrades. Ask them about reliability issues with increased power and figure out how much risk you want to take. That's what I'd do, personally.

Is rebuilding the pump cost effective? Who makes a quality rebuild kit for a reasonable price? Same question for the bearings and gaskets. Will I be able to do a tune reflash with a VAG-COM (If I decide to keep it a TDI)?

tripod · « **Reply #13 on:** April 23, 2009, 03:12:14 pm »

jtanguay · « **Reply #14 on:** April 25, 2009, 04:19:54 am »

the '01 alt for automatic will probably be 120 amps or so. could be less because it doesn't have the glow plug heater system though.

if you're getting air bubbles to the pump, it won't run right regardless. letting the pump sit dry or even a little dry is really bad too. i bet if you just fix the air leak issue the engine will run good. unless the pump is high miles (about 400k+) or has been run with bad fuel, they rarely ever go bad.

you could always just say screw it to getting your ecu chipped and just use some resistors on all the sensor wiring. that way you only need to plug in 3 things. needle lift sensor (no.3 injector), injection pump harness, and crank sensor. it will run pretty close to an mTDI in that weather will affect it a lot more, but its wayyy less complicated. cheap mTDI pumps are very hard to come by, and often aren't very reliable unless built by someone who knows what they're doing.