TDI HEAD PORTING

[JFettig]

I feel like I shouldn't update this because I haven't sorted it completely.

I installed my ported head 3200 miles ago. At the same time I upgraded rods and pistons, resealed my injection pump and re-did my glow plug harness(used proper 4 wire harness).

The most important thing to mention first is that us two non engine machinists did the valve job.

First off it pulls really nice, I gained 200rpm on the low end. My turbo ran out of breath on the top end because it was so small and flowed so good, I had to cut boost earlier but it still pulled as good. Now I have a bigger turbo and it pulls nicely to 5500rpm, or higher(vcds only reads to 5355rpm).

Overall performance increases are awesome.

Now the bad - its most likely my change to the glow system, but it could be my valve job or reduction in swirl. It doesn't start nice with the stock glow plug duration, if I glow it multiple times it starts great, if I unplug the CTS and glow it longer, it starts great, boom its on, no excess cranking. Otherwise, it takes some effort to start.

[RabbitJockey]

what kind of cold temps are we talking about here?

how is mpg?

any white smoke?

and perhaps describe what u did to the valves and and another machinist who speaks the machinist language can say if any of that could be a problem.  maybe even just doing a compression test would give you a good idea. 

sounds promising tho, if a tdi can make good power to 5500 and peak power near or above 5k u could make some serious power at relatively low boost and less stress on the engine.  what turbo are you now running?

[JFettig]

Anywhere from +40F to -10F is about what I'm experiencing now. +40 it will start with a little more cranking than normal, just a little glow(unplugged CTS) and it'll fire right up. I have a new tune waiting to go into the car tomorrow morning with a different glow map which should glow for a few seconds at +40 and increase duration all the way down.

Only white smoke I get is right away on a hard start, if I glow it long enough, no white smoke. On a hard start it probably lasts 10-30 seconds.

MPG is +2-3mpg from a year ago, roughly 42mpg vs 40mpg

Based on a couple opinions, I did not lap the valves, we just cut the seats with a carbide cutter and ground the valves with a valve grinder. Also back cut them. They all held vacuum when tested(I forget what the actual # was)
I am running a GTB2056VL now, at 5500rpm I'm only making around 18psi. This was calculated based on a GT2056 map from turbobygarrett.com - not sure if its right but its happy. At 5000rpm I am still making 25psi

[JFettig]

will do a compression check soon - my new tester is defective.

Additional glow and it starts much better. Not as good as before but it'll start up first try.

[keaton]

I would be very careful touching the swirl bump on a PD head, part of the injector seat is there.

here is some other useful info

PD130/150 Port molds
http://forums.tdiclub.com/showthread.php?t=300245&highlight=cross+sections

PD Cylinder head cross section
http://forums.tdiclub.com/showthread.php?t=374419&highlight=PD+Head

cylinder head swirl & flow data
http://forums.tdiclub.com/showthread.php?t=307098&highlight=cross+sections