Malone's MK3 TDI

[G60ING]

I love it

[theman53]

Sucks that things got stolen. I have a lot of VW stuff and I try to keep it out of parking lots, but something like you were doing I wouldn't have thought it bad or expected anything close to that to happen.

At least at home the 100lb german shepard/wolf mix and an array of weapons and ammo have curbed those who have come unexpectedly. Nothing like the sound of our dog growling and the ring of a shot gun to make those try and find an easier target.
What do you plan on doing and how fast now that more pieces need to be made?

[malone]

Got a K03/K04 hybrid turbo for a good price. It's a direct replacement for the stock K03 in the AHU TDI. It realistically adds maybe only 5-10HP without increasing smoke+EGT, although an AHU TDI ran high 14s in the 1/4 mile with it.

I was tempted to get a VNT-17 but right now it's over $800 and it requires custom IC plumbing. I don't have the resources to fabricate/weld so it may ultimately cost twice as much as the K03/K04. I wish G60ING could duplicate his IC plumbing for me, or in fact his entire turbo+EGR setup, it looks good!

Another reason for sticking with a 'stock' turbo is that it's better for compound charging if I ever go that route. It keeps everything as simple (close to stock) as possible. Typical VNT issues are also a bit harder to diagnose in a compound system.

[G60ING]

Sorry for not reading about the stolen turbo part.

There is no way that I could duplicate the intercooler plumbing without a TDI Mk3 to base the pipes off of because my G60 intercooler is way different than the Jetta one:

G60 Rado intercooler:



Mk3 TDI:


I'd also consider doing a FMIC on the mk3 because its so easy when compared to the corrado.

[G60ING]

I hope all is well and you are too busy driving and chipping to post

[malone]

While we were going to finish fitting the VR6 brakes a couple weeks ago, I discovered that my VR6 DE calipers, brake lines, and a few other small bits were stolen with the stock turbo+downpipe. I couldn't find used VR6 calipers so I recently ordered 'remanufactured' ones and I expect to get them in tomorrow. I can't wait to drive this This weekend is a possibility.

I heard about your turbo, Frank. Did you get it analyzed yet?

[quietmission]

any updates on this? 

[malone]

I drove it home a few days ago. Really happy with it. Here's a quick snap from a few minutes ago:



Today I installed a Stage 1 tune and it feels strong. It's nowhere as quick as my old 1.6TD with GT20 turbo though

Plans for this Saturday:

- Install an electric 6-8 PSI fuel lift pump.
- Hammer the injection pump. The IQ is way off (beyond the VAG-COM adjustment range) and my idle vibrates more than it should.
- Install complete OEM 0.216 injectors.
- Install gauges.

2-3 week plan:

- Install ECU emulator so I can do live-tuning while the car's in motion. My favourite tool. Someone will drive while I operate the computer, of course.

6 month plan (I want to bring this car into near showroom condition and then enjoy it for many years to come):

- 2.9 bar MAP sensor and 21 PSI tune.
- Full interior restoration with bolster seats i.e. MK2 recaros or MK5.
- Full repaint.
- 6 speed 02M transmission with Peloquin LSD.

This car has great off-boost acceleration. I think the Colt Stage 2 cam helped - it noticeably increases low-RPM torque according to dyno charts. The K03/K04's boost ramp-up is also very smooth and not too sudden.

One thing I like more about this TDI (compared to my old 160-192whp 1.6TD) is the low-RPM torque. Passing cars at 2000 RPM feels so smooth and effortless. Awesome.

Someone has been test fitting a G60 on a TDI for me. Obviously it isn't 100% bolt-on, but it doesn't look like too much work. I am kind of shying away from it now though, as I don't feel the need for lots more boost. My goal is to have a simple and low-maintenance daily driver with mostly original/OEM parts.

[malone]

A fresh swap project like this does not come 100% problem-free, of course:

- The car has the original TDI O2A transmission and an upgraded SBC clutch, but the shifter feels very notchy. It's clunkier than a MK2 transmission, if that gives you an idea. Any suggestions on where I should look to make it smoother? If I can fix this, then I probably won't bother with the O2M 6-speed swap. The other related issue is that if I lift the clutch pedal even just 1cm off the floor, the gears can grind during shifts.

- Cruise control does not work. I'll probably want it during a 2012 Summer road trip. This Golf originally did not have cruise control, but I did transfer the entire fusebox, pedal wiring, and dash wiring from the '98 Jetta TDI. The Golf also did not (and still does not) have ABS.

[4wheeler]

Cruise for an AHU needs the brake and clutch switch hooked up.
it doesn`t need ABS.
How did you make it run without the brake and clutch switch hooked up?

[malone]

I'll check the brake and clutch switches. The only fault code I saw was EGR, which I deleted in the tune (for now).

I have a feeling that the cruise control stalk (on the steering wheel column) isn't wired in. Should be easy

Thanks

[the caveman]

You go into measureing blocks to check all your cruise control signals[ sorry, I don't remember which channel] The important item is the brake switches. They both have to switch on/off at exactly the same time

[malone]

The fuel timing didn't look great (I'm very picky about details like these):



This issue is very common and it's apparent in at least half of VE TDIs. Optimizing the timing will restore power and possibly fuel economy.

An 5-9 PSI electric fuel lift pump was added last Saturday. As a result the fuel timing is noticeably improved.



It pulls harder in the upper RPM range now. Another common cause for poor timing is the collar walking out of the case relief valve (see middle valve in the picture below). The case relief valve is in the diesel fuel injection pump:



The collar can be pressed back in, but it'll walk out again especially if more power is in the picture. To prevent this from happening, I will do the keystone mod:



The above picture is a homemade keystone courtesy of StealthTDI. I will be using a different design made of steel.

I'll post the updated timing graph after it's done.

The following mods were also done last Saturday:

- Euro 0.216mm injectors
- Hammer mod (injection pump calibration). Originally 0.8 IQ, now 3.2 IQ.
- Stage 1.5 ECU tune

Boost looks good and I haven't done any tweaking yet. Leaving it at just shy of 18 PSI sustained for now (typical max. safe boost for a stock K03 turbo):



I would probably estimate it at 190ft-lb torque right now. When I had stock injectors and a Stage 1 tune, a MK3 VR6 buddy commented that it pulls like a VR6. But there is much more potential as it's currently running a mild tune and the K03/K04 hybrid turbo is designed for 22 PSI. I am happy with the way it performs now, though.

Maybe I'm spoiled by my old 2006 MK5 Jetta TDI (now my wife's), but the AHU vibration at idle is a bit much. It's smooth as glass once the RPM is >1100. I need to ensure that I have stock TDI mounts installed. If not, time to order some.

[rallydiesel]

I've never heard of this keystone mod. Can you describe it a little further?

[J Z]

I've never heard of this keystone mod. Can you describe it a little further?

x2