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Model Specific Questions and Info => MK3 Golf/Jetta and B3/B4 Passat => Topic started by: vanbcguy on September 12, 2015, 03:35:38 am

Title: Petra Passat
Post by: vanbcguy on September 12, 2015, 03:35:38 am
Meet my new friend Petra:

(http://images.tapatalk-cdn.com/15/09/12/78ff50f475f7471abe612321aba70a30.jpg)

She's currently has an AAZ but an "Ecodiesel" version with a non - LDA pump....

(http://images.tapatalk-cdn.com/15/09/12/e666ac0a3baddb4c58db8e0931aa0d3c.jpg)

The plan is to drop my M-TDI from Jezebel in here, but this car is so clean and original I'm having a hard time convincing myself to dig in!

(http://images.tapatalk-cdn.com/15/09/12/8f19615d35b527c56c7ed6e380c3649b.jpg)

The car is super clean and kid approved. I definitely notice the lack of HP compared to Jezebel though!!
Title: Re: Petra Passat
Post by: vanbcguy on September 12, 2015, 03:41:51 am
So far I've:

- replaced all 4 wheel bearings - they were all toast despite the low mileage
- new strut bearings and control arm bushings
- alignment
- new hatch struts, wipers all around, new stereo


Coming up next:

- clear signals for the front
- new ABS accumulator
- new ABS wheel speed sensors on at least the right rear
- fix the left rear power window - currently has a 2x4 holding the glass up
Title: Re: Petra Passat
Post by: vanbcguy on September 12, 2015, 03:45:16 am
(http://images.tapatalk-cdn.com/15/09/12/3a8c69ca03346f6c0e0af58bd468b0ac.jpg)

My lineup at the moment...
Title: Re: Petra Passat
Post by: vanbcguy on April 20, 2016, 11:51:59 pm
(http://uploads.tapatalk-cdn.com/20160421/03eafa722ee3ba4c0d53019dc899ab6a.jpg)

+

(http://uploads.tapatalk-cdn.com/20160421/07eb394fa97f280834426cafa3e3dff1.jpg)
(http://uploads.tapatalk-cdn.com/20160421/f722a51ac92a24776c452d5185375bb0.jpg)

=

(http://uploads.tapatalk-cdn.com/20160421/8233818d5d37d1de320ce50293bafbd7.jpg)
Title: Re: Petra Passat
Post by: vanbcguy on March 30, 2017, 03:20:14 am
Haven't updated in a while!

So the day finally came to transfer my M-TDI over to Petra... That also brought about the end of service for my Jetta. After nearly 9 years it was time to say goodbye to an old friend...

(https://uploads.tapatalk-cdn.com/20170330/425bc5d1e783f62c1ea058e3b5d801e4.jpg)

I had originally planned to put the AAZ from the Passat in to the Jetta; the amount of work plus the challenges of dealing with two incapacitated cars at once put the kibosh on that. After sitting for a couple of years the Jetta really wasn't in good shape either - I hadn't realized the trunk was leaking most of that time, the rockers were rusting pretty good, mould started taking over in the interior and the body had 350,000+ km on it. Goodbye!

I honestly wasn't too eager to tear in to Petra. She's such a clean original car I felt kind of bad unbolting things as we all know cars never quite go together exactly the way they came apart. Still the thought of another year trying to push a heavy wagon up mountain passes with 70ish HP wasn't really all that appealing. I have to say though - EVERYTHING on this car comes apart easily. Most bolts come out looking brand new. I'd attribute a lot of that to the fact she still has her belly pan - it really helps reduce the amount of crap getting in to the engine bay.

After a few days of after work labour I have a TDI in my B3:

(https://uploads.tapatalk-cdn.com/20170330/8a5b9cebfecfbe9fdfcef1148d7ac670.jpg)

I should be in a position to fire her up tomorrow evening. Looking forward to hearing that TDI run again...

The astute viewer might notice the oversized oil cooler - there's some posts of mine from a few years ago talking about the higher oil temperatures I had been seeing with this engine. I decided to upgrade since I had everything out and the cooling system drained already; the larger cooler is from a V6 Passat 4motion. There's just enough room to do a filter change with a good front engine mount:

(https://uploads.tapatalk-cdn.com/20170330/3370b0b6541f25d7dcad75b970423326.jpg)

Looking forward to driving this car with some actual power!



Sent from my XT1097 using Tapatalk

Title: Re: Petra Passat
Post by: libbydiesel on April 01, 2017, 01:15:30 pm
Awesome!  Keep up the posts. 
Title: Re: Petra Passat
Post by: vanbcguy on April 02, 2017, 03:17:59 am
Fired her up today! Forgot how much smoother the TDI runs compared to my AAZ.

Haven't been able to get the clutch bled yet. Going to take a cracked at it again tomorrow.

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Title: Re: Petra Passat
Post by: TylerDurden on April 02, 2017, 10:17:04 am
If you don't mind me asking...

Which coils did you use on the rear, and did they restore to stock height?
Title: Re: Petra Passat
Post by: vanbcguy on April 02, 2017, 11:41:56 am
I actually went for coilovers - brand is ST, a division of KW. The car is a couple of inches lower than stock.

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Title: Re: Petra Passat
Post by: TylerDurden on April 02, 2017, 02:54:28 pm
10-4, Thanks.
Title: Re: Petra Passat
Post by: vanbcguy on April 02, 2017, 03:08:06 pm
First drive today!

Had more success bleeding the clutch with an oil can pushing fluid upwards rather than trying to suck air downhill with my Mityvac. I'm still not 100% on it - I have to have the pedal RIGHT to the floor so I think there's still a little air in there. However she moves!! (https://uploads.tapatalk-cdn.com/20170402/97bf704acb0518c585d86e3968027de7.jpg)

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Title: Re: Petra Passat
Post by: vanbcguy on April 03, 2017, 03:21:56 am
Took a good 30 minute run this afternoon. Clutch just needed some exercise, it's behaving normally now. The car is shifting perfectly which is a bit of a relief.

Haven't managed to get it hot enough to kick the fans in yet - no reason they shouldn't work but I'll feel better once that happens. Temp is peaking at 90C on the factory gauge which is perfect - I was regularly seeing 100+ with the AAZ. There was a fair bit of black slime in the old cooling system but the heater core is the only thing left from before. Rad is brand new.

Driving to the fabrication shop tomorrow - exhaust and intercooler time!

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Title: Re: Petra Passat
Post by: vanbcguy on April 07, 2017, 10:20:50 am
Car will be ready probably towards the end of next week - kind of works out perfectly as I'm in the middle of moving - if it were here I'd undoubtedly be fiddling with it rather than packing... Ha.

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Title: Re: Petra Passat
Post by: vanbcguy on April 16, 2017, 06:33:26 pm
Fabrication continues...

(https://uploads.tapatalk-cdn.com/20170416/b59d19337d4508e503bc172727283f55.jpg)

(https://uploads.tapatalk-cdn.com/20170416/7f7b73e49eb67dcc0f7f3b96624672d7.jpg)

(https://uploads.tapatalk-cdn.com/20170416/33b4048eec1d79f4da169269d5259177.jpg)

Sad I had to remove the stock airbox - just couldn't fit it in there with the pipe work.

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Title: Re: Petra Passat
Post by: vanbcguy on April 25, 2017, 08:13:06 pm
Completed install looks great!!

(https://uploads.tapatalk-cdn.com/20170426/69bf47979540880f609d635a4fbca20f.jpg)

They had to trim the lower grille a bit...

(https://uploads.tapatalk-cdn.com/20170426/27d4a52b34df796385dc2b5b4c835fc9.jpg)

Support was added behind the lip so it doesn't flap around. I love this:

(https://uploads.tapatalk-cdn.com/20170426/aaf7b137542bf60453012a228251364b.jpg)

No VNT controller yet so I'm just driving around with the vanes open. The turbo doesn't spool till about 4500+ right now. Sure is fun once it does though! Ha.

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Title: Re: Petra Passat
Post by: libbydiesel on April 25, 2017, 10:41:11 pm
Nice!
Title: Re: Petra Passat
Post by: vanbcguy on May 16, 2017, 03:17:33 pm
Well I can definitely say this motor mount setup is a bit excessively stiff. I decided to put a G60 solid transmission mount in along with a BFI Stealth front mount, and a hydraulic rear mount. I'm only 250 km in so far, not really enough time for them to be broken in but I'm currently not really enjoying the car any time I'm in traffic.

I had essentially the same setup on my Mk3 but with a hydraulic transmission mount instead. It's REALLY hard to get at the trans mount on a B3 with ABS so I thought the solid mount might make more sense (less chance of failure) but now I'm wondering if that was the right move...

I've raised the idle to about 980 which at least let's me see straight at idle but it ain't gonna cut it. Will probably run till July and see if things settle down at all, then start changing things if not.

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Title: Re: Petra Passat
Post by: libbydiesel on May 16, 2017, 03:24:36 pm
That's a bummer.  It is amazing how much of a difference there can be with different mounts.  Before delving deeply into the mounts, though, make sure you take a VERY critical look at the exhaust mounting.  A tremendous amount of vibration can be transmitted from the exhaust.  An option would be to disconnect at the turbo and see if that makes a significant change. 
Title: Re: Petra Passat
Post by: vanbcguy on May 16, 2017, 03:57:16 pm
I should mention that the exhaust mounts are also all brand new; I'm happy with the exhaust routing, everything has been done using the factory mounting points, etc. I had just as much vibration before the exhaust was installed too; I think I'm probably ok there.

The Turbo to FMIC pipe could probably use a bit more isolation; there's a bracket they made I can unbolt to verify. I really feel like it's the trans mount though. It came with a BFI mount set; they brag about how their solid trans mounts are stiffer than the 'competition' too so that's probably where I should focus my efforts first.

I also might be wise to retard my timing a little. I'm set for 12 degrees BTDC, but with my .275 nozzles that might be a bit excessive. It certainly sounds like a truck below 3K RPM or so... I can't imagine the injection duration is particularly long with the 11mm pump and the huge nozzles.
Title: Re: Petra Passat
Post by: theman53 on May 24, 2017, 04:56:30 pm
give it 1,000 miles and see, mine got more livable after that
Title: Re: Petra Passat
Post by: vanbcguy on June 09, 2017, 01:57:54 am
Well I'm at about 400km since I did the swap... That's 240 miles for all y'all south of the border. Pretty much all in traffic so quite a few hours, probably 15 or so. The mounts have tamed quite a bit - it's still pretty rough but if it softens up as much again as it has so far I'll probably be good to go.

Got my summer tires on finally too. About time!

I'm working on my VNT controller again - the one I ran in my Jetta was a prototype board so all point to point wire connections, no filtering capacitors, just quick and dirty. Way back when I did things the first time I drew everything up in Eagle and had a couple of bare PCBs made. Soldered up one finally and started testing tonight - so far so good. I'm missing a library I used previously that makes my EGT sensor work in a reasonable time period, gotta get that sorted but everything appears to be bench testing ok so far.

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Title: Re: Petra Passat
Post by: vanbcguy on June 15, 2017, 02:25:26 am
Have my new VNT controller assembled and have been bench testing. Have made a few programming changes to deal with some things I remember from before. Added a "cooldown" feature that will change the backlight color on the LCD to blue when the engine is at safe shutdown temperature (it already does green for "normal", yellow for EGT warning and red for EGT alarm, it starts venting pressure from the LDA at the same time when it hits the alarm level). Cleaned up a couple of other things in the code.

Cabling should show up tomorrow so I can build the harness. Then I start cramming it in the car...

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Title: Re: Petra Passat
Post by: libbydiesel on June 16, 2017, 12:03:06 am
Very cool! 
Title: Re: Petra Passat
Post by: vanbcguy on July 09, 2017, 03:09:27 am
Finally had the time to finish off my controller. It'd been bench tested and appears to be functional. This one has been designed to be waterproof so it can be mounted under the hood somewhere. I might see if I can fit it in the rain tray though I suspect that'd be a bit tight space wise.

(https://uploads.tapatalk-cdn.com/20170709/332afe257ebcf20c8f0fa0580b24b357.jpg)

Everything that could move received a liberal coating of hot glue after that. The box is industrial waterproof / dust proof rated along with the external connectors. Oh also not shown are the clamps on the air air lines. Ha.

I still have the second pressure sensor on board which I always intended to use for measuring exhaust manifold pressure. I haven't ever added that to the code though, so for the moment it's just along for the ride. It does give me a higher pressure sensor I can use though - the main one is a 2.5 bar relative and I believe the other one is a 4.0. Add 1 to those values to see how they'd compare to a typical absolute pressure sensor like you'd find on a factory car.

I reeeallly want to experience driving my car with boost again!

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Title: Re: Petra Passat
Post by: libbydiesel on July 09, 2017, 08:32:20 pm
That looks awesome.
Title: Re: Petra Passat
Post by: vanbcguy on July 11, 2017, 10:50:25 am
Repaired my cluster yesterday... Mine is still analog - has a physical odometer and the older style gauges that are electric rather than electronic.

My clock was resetting almost every time I started the car - this was despite the usual things being in good health (battery cables, grounds, etc). As I suspected there was an electrolytic capacitor that had swollen and popped on the board. I followed the traces and they went right to the clock module - jackpot! Replaced that along with the other matching capacitor on the board with new ones. Cost: $1.50 CAD.

I also had issues with my fuel / temp gauges. They were randomly dropping down to 1/4 scale then returning part way to where they should be. The result was I couldn't really ever tell where my temperature was at which ain't good with road trip season starting. I replaced the old obsolete 10V regulator with its modern generic equivalent. The old regulators have the pinout backwards so the new one needs to be installed upside down. If you buy one from VW you get the new regulator with a brass spacer to screw it to the heat sink for about $40. The regulator itself plus some small washers to use as a spacer cost about $3.00.

Both fixes were successful - had a bunch of errands to run yesterday and saw my fuel level and temperature stay right where they should be plus my clock showed the correct time without resetting. Score!

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Title: Re: Petra Passat
Post by: vanbcguy on July 14, 2017, 09:57:03 pm
Made up a mounting bracket for my VNT ECU - fits where the stock ECU would be if the car had one:

(https://uploads.tapatalk-cdn.com/20170715/fd4484cd94678f11818c627b28876b89.jpg)

I also updated my code to work with a VW N75 valve rather than the GM ones I've been using - the GM ones are super noisy while the VW one is barely audible. Unfortunately way more expensive though - I'm going to keep a GM one for LDA cutoff at high EGTs though I don't think I'll be able to make it quite as progressive as it was previously.

For comparison the wastegate VW valves run at about 8 Hz, the GM valves at 30 Hz and the VNT VW valves run at 250 Hz.

Oh yeah, lots of driving around today - my cluster repairs have worked great. Super consistent gauges and a working clock!

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Title: Re: Petra Passat
Post by: air-cooled or diesel on July 19, 2017, 08:45:28 am
any update on your petra and if your vnt ecu install worked out, got boost?
Title: Re: Petra Passat
Post by: vanbcguy on July 19, 2017, 11:05:02 am
Still finishing up wiring - as of yesterday all the boost and vacuum lines are installed, the CPS and TPS are connected and the solenoids are wired up. I've tested that stuff and verified it all works.

The VW N75 valve is virtually silent compared to the GM ones I used before - VERY welcome change. Appears to have the same range of duty cycle control as the GM solenoids too which is awesome since I don't need to change my maps.

Hoping to get it done today. All that's left is to run the wire for the display in to the cabin and to connect the power up permanently.

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Title: Re: Petra Passat
Post by: vanbcguy on July 20, 2017, 02:00:29 am
Drove today with the controller in place finally......

.....
.....
.....
.....

...and discovered a massive boost leak. One of the mounting tabs on one of my boost pipes peeled itself off the pipe at some point leaving a giant gash. Not too happy about that.

Gave some tape a try as a short term fox but it burst almost immediately, guess 25+ PSI is too much. Gonna try a muffler bandage or something tomorrow then try and head out to the fab shop to get them to fix it.

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Title: Re: Petra Passat
Post by: vanbcguy on July 20, 2017, 07:53:00 pm
Made up a quick rubber patch and headed out to the fabricator that did my intercooler install this morning. They repaired the damaged pipe and spotted another bracket that had cracked, guess they aren't used to the vibrations of a diesel! The other bracket (which supports the air filter) was triangulated and is much stiffer now.

After all of that I finally got to drive with boost! Woohoo! I cranked my fueling down a bunch when I was driving without the turbo, my EGTs are peaking at under 600°C right now so there's room for more fuel. I have the boost dialed back a little too.

The noise of the air rushing through the K&N is down right irritating. It's LOUD, and not in the "turbo whistle" way, more in the "crazy amount of air rushing through a fine metal screen" sort of thing. I'm going to have to sort something else out. Really wish we could have kept the stock airbox... I need something that has its outlet closer to the bottom though.

Oh yeah, my boost controller appears to be working fine. I'm seeing the vanes fully closed a bit more than I remember with my Jetta - the FMIC vs the AWIC might have something to do with that. I also reclocked the turbo when I had the engine out so my actuator might need some adjustment. However it is certainly doing its job and keeping boost regulated well!

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Title: Re: Petra Passat
Post by: air-cooled or diesel on July 21, 2017, 09:21:51 am
The noise of the air rushing through the K&N is down right irritating. It's LOUD, and not in the "turbo whistle" way, more in the "crazy amount of air rushing through a fine metal screen" sort of thing. I'm going to have to sort something else out.

you can try to make another circuit board, this one you can put turbo whining sounds on it, adjust for rpm and vss, perhaps hook up to former ecm connectors so it can sense these. it would have to be like really "LOUD" (can you hear anything over this &the intake sound?), and hook it up to like your sound system. lol.

id say strategic sound deadening. perhaps at,near the base of the intake filter (area), put a type of contraption (its hard to print what im visualizing) that will go around (intake or filter,base) and is angled away from passenger cabin (cannt think of angle, ?running parallel to firewall?) perhaps with angles or tabs, again away from cabin, (or slightly in on its self) and add sound deadening, to deflect, lessen sound.
Title: Re: Petra Passat
Post by: vanbcguy on July 21, 2017, 09:28:18 pm
I was looking at some ammo boxes today that might make good filter housings. The price was a bit dear so I left that for another day, but I could see it working. Of course the alternative is to spend a bunch of money, get some of the pipe work redone and use my factory airbox like I wanted to in the first place... I also thought about just cutting a hole in the factory airbox and putting the cone filter in there (the reason I can't run it is the top outlet, my turbo to IC pipe is in the way).

Did some more tuning and adjustment today. Messed with the actuator and stop screw settings; got the turbo in to the actual control range of the N75 under most circumstances. I think the stop screw could still come out another turn but that requires me getting the car in the air and yanking the belly pan so it won't be happening for a while. I could probably do with shortening the actuator rod a little too but I think I need to pull the turbo to do that. The actuator bracket had a little adjustment but it's at the end of its travel now, any further adjustment will have to be done with the turbo out of the car. Ugh.

Fuel screw went in about a full turn. Still virtually smoke free with the pedal to the floor and EGTs still below 650C so I can still push a fair bit harder. I think the FMIC is providing much better IATs than my AWIC was as I had no trouble hitting 850C in the Jetta. Now I have a heavier car and I'm running with about 5 PSI less boost but seeing lower temperatures. The fuel screw is almost to the collar now.

I think the stop screw must have been pretty wrong on the Jetta too as I'm fairly sure I cranked it out a half turn or so while I had the engine out, then another full turn today. That's a pretty big adjustment. The boost comes on pretty fast now, first time I've been pushed in to the seat since I bought the car however long ago now.

I fixed a few things in my Arduino code too which has allowed me to increase the sampling frequency. I think the VW N75 valve is faster acting than the GM one I was using too - I'm seeing much more immediate response from the turbo when the duty cycle changes. I'm having to remove some of the code I had previously to try and overcome lag in the control system.

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Title: Re: Petra Passat
Post by: vanbcguy on July 21, 2017, 11:54:46 pm
(https://uploads.tapatalk-cdn.com/20170722/bc8215d9583d328369ce292e631c64f2.jpg)

This is where I'm at. The actual control is pretty good, boost is pretty close to requested. However the duty cycle is jumping around a lot more than it needs to - that'll wear out the VNT mechanism in the long run if I don't calm it down. I need to make it a bit less aggressive.

The "stuttering" just over 5k RPM is actually the LDA control starting to vent pressure - I have it set to act somewhat like a rev limiter as well as limit EGTs. I actually didn't realize it was coming in to play, I need to turn it down a bit as I wasn't expecting it to have any impact till closer to 6k RPM.

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Title: Re: Petra Passat
Post by: vanbcguy on July 28, 2017, 10:21:03 pm
1200 km of road trip later....

(https://uploads.tapatalk-cdn.com/20170729/a10de2c3b20001b6023da3412e027c66.jpg)

Lots of sustained high speed driving - limit is 120 km/h up the island highway, complete with the odd stoplight. Had a few opportunities to do WOT 0-120+ acceleration runs. Very fun. Nice tire squeak going in to second.

I somehow set out with my mini laptop with a dead battery so had no opportunities for tuning or logging. I know I need to make some tweaks still, I'm still having some flutter at 3k+ and my 29 PSI target. It'd not varying a ton but it's hunting around as detailed previously.

EGTs are great. The new intercooler is definitely doing a better job no two ways about it. It was hot today - 30+C. Uphill WOT  run up to 140 umm I mean 120 km/h and EGTs still safe. Oh yeah fully loaded down with camping gear including a full load on the roof! Well minus the 20L water jug that disappeared at some point along the way... Oops.

Yesterday was about 5 hours driving all together, all mountain highways. The car is a joy to drive in that scenario - it's what she's built for. Power delivery is super smooth. Mmmmm...

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Title: Re: Petra Passat
Post by: vanbcguy on August 02, 2017, 07:34:51 pm
Eureka!

I've been having issues stabilizing control over the turbo all the way back to my Jetta. Yesterday I figured out that there was a bug in my code - I wasn't actually acting on the latest data sample when I was making control decisions. Effectively I was setting the turbo to handle what I'd read 50-100 ms ago, not "now". Duh. It's leftover from me making some changes in the control logic that probably stretch back to the start of the damn project.

Well that's fixed now! I have stable control. Here's a solid pull through 3 gears...

(https://uploads.tapatalk-cdn.com/20170802/2cef795cda307bc655c7be110b7ea99d.jpg)

A little overshoot but no big deal, hitting 2.15 bar with a 1.95 bar target. I can deal with that - I could probably tone it down but I'm good with it.

EGTs hit about 650°C and stay pretty much flat - that's awesome too. Means I can basically have it floored all day without having to worry.

Small stop screw adjustment on the turbo wouldn't be the worst thing, could close the vanes a hair more. I probably still could do with having the actuator rod just a wee bit shorter but I'm really not interested in pulling the turbo to do it.

Anyhow glad that's finally sorted. I'm sure my car will appreciate being used as a car eather than me just driving around in circles to the same highway on ramp again and again to go WOT.

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Title: Re: Petra Passat
Post by: libbydiesel on August 03, 2017, 07:08:15 pm
That looks awesome.
Title: Re: Petra Passat
Post by: vanbcguy on August 08, 2017, 03:07:04 am
Nice 8 hour drive Vancouver to Spokane, WA...

(https://uploads.tapatalk-cdn.com/20170808/6532873eae42c35babaa0dae8bf13e4b.jpg)

Everything is running well. Definitely a lot more fun to drive with the TDI vs the AAZ!

The astute might notice my new wheels. Liking them big time!

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Title: Re: Petra Passat
Post by: air-cooled or diesel on August 08, 2017, 07:55:41 pm
both the rims you have on this page in pics look good.

isnt this the last model that had the 4bolt weaker pattern. i had always thought the mk2 was a little big for a 4bolt wheel pattern, and the mk3s (&b4 models) were a good size too big for the 4 bolts. ive never had a problem with this, although know its a 'design defect'. wasnt it here where the whole industry went to a -minimum of the 5bolt pattern, except for certain small models. the 5 bolt pattern is at least 20% stronger @ the attachment.
Title: Re: Petra Passat
Post by: vanbcguy on August 08, 2017, 08:01:19 pm
VW did 4-bolt on everything until they went for the VR6. The "load" of the car is taken up by the clamping force between the wheel and the hub, though the bolts are definitely involved in torque transfer. I always figured if a G60 Syncro could handle 4-bolt a TDI should be fine!

I liked my last rims looks wise but they were a no name brand and ended up bending quite easily. Never tagged a curb or anything, just whatever bumps and potholes I'd encountered in normal driving bent two of them.

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Title: Re: Petra Passat
Post by: vanbcguy on August 21, 2017, 07:55:11 pm
Turbo carnage!

(https://uploads.tapatalk-cdn.com/20170821/cdad08035dd75574ccc3b6efa84e323d.jpg)

When I swapped the engine in to the Passat I noticed a little nick in each of the primary compressor blades. I wasn't sure what was going on - at the time I thought since they were all pretty uniform it must have been made that way. Guess not!

Pretty sure I fatigued the turbo pretty good back when I had the engine in the Jetta. I know I hit 35+ PSI more than a few times. Add in the episode with the big hole in my boost pipe and I can explain why I wasn't seeing boost come on as quickly as I would have expected...

Ever since I got the control system together in the Passat I've been noticing it was taking a lot more N75 duty cycle to get the boost I was requesting than I was seeing in other people's logs. Over the past while I've been really noticing it wasn't behaving right at all - I was having trouble achieving my requested boost on some longer pulls where I would have expected overboost to be the issue. Then last week it finally gave up the ghost...

(https://uploads.tapatalk-cdn.com/20170821/52220b19e433d028977f74d045e37cce.jpg)

Boost suddenly dropped off, then the turbo started whining like crazy, though it was still producing boost. I prepared myself for a possible runaway and made my way back home. Opened it up today and found the carnage in the first photo.

Well, now I know why I was having to push the turbo so hard!

There was a bunch of grey fuzz and n the turbo outlet which I'm expecting is powdered turbo wheel. Going to have to clean out my IC for sure. Hopefully not too much made it in to the engine.

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Title: Re: Petra Passat
Post by: vanbcguy on August 22, 2017, 04:46:36 pm
Siiiiiiigh. From the "boy, do u feel stupid" department.....

Noticed when I was taking everything apart I was missing a rubber sealing ring from my air filter. Figured I must have not used it in the end (it was a thin ring to adapt the cleaner to the pipe I'm using but not strictly necessary). Welllll it isn't in the box. And the black fuzz that's all through my intake? Yeeaaaahhh I tried hitting a bit of it with my torch. Burns like rubber. Smells like rubber.

D'oh.

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Title: Re: Petra Passat
Post by: libbydiesel on August 23, 2017, 07:28:26 pm
Bummer!  Do you think that the missing sealing ring caused the damage or just over-speeding?
Title: Re: Petra Passat
Post by: vanbcguy on August 23, 2017, 07:46:29 pm
It definitely caused the damage. There's shredded rubber everywhere. Now I'm not so sure anything happened beyond the ring getting loose, though I still think my turbo wasn't totally happy to begin with.

Expensive mistake but there you go. All I can do is blame the engineer, myself!

New turbo ordered...

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Title: Re: Petra Passat
Post by: vanbcguy on September 08, 2017, 09:22:09 pm
Finished getting the turbo swapped out today. Had to use both the compressor and turbine housing from my old turbo as they were both a bit different despite both turbos being a GTB1756VK.

The replacement turbo seems to be spooling quicker than the old one. I'm also seeing a lower (vanes more open) N75 duty cycle too. I only have one log that's just me driving around the neighbourhood but my cruising vane position is much better.

Expensive mistake to make. If anyone wants a GTB1756VK that needs a new compressor wheel hit me up!

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Title: Re: Petra Passat
Post by: air-cooled or diesel on October 18, 2017, 04:21:45 am
so, i ve been meaning to ask a question in the m-TDI section. not really to you van, as your motor is rather hopped-up, but in a close to stock set up and/or some what extra output, perhaps some of it being a turbo. whats about the mileage? id prefer to go with a manual,mechanical wastegate set up.
Title: Re: Petra Passat
Post by: vanbcguy on October 18, 2017, 11:25:42 am
I've been getting around 5.5L/100km on my last few road trips (about 42mpg). I don't drive with a particularly light foot and that's been with bikes on the roof too...(https://uploads.tapatalk-cdn.com/20171018/fda23c6b347b890565dc8428d345ddb8.jpg)

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Title: Re: Petra Passat
Post by: air-cooled or diesel on October 18, 2017, 12:23:28 pm
ok so now i need more info, cause as you all know i have at least 1 mk3. and im getting about 40mpg w/o a light foot at hiway speeds, 70mph or so. so what i had heard was an m-TDI may get 35mpg, so what else are you doing? cause you have performance options, i for one figure 5 gear, youve swapped in a higher one.
Title: Re: Petra Passat
Post by: vanbcguy on October 18, 2017, 02:24:23 pm
ok so now i need more info, cause as you all know i have at least 1 mk3. and im getting about 40mpg w/o a light foot at hiway speeds, 70mph or so. so what i had heard was an m-TDI may get 35mpg, so what else are you doing? cause you have performance options, i for one figure 5 gear, youve swapped in a higher one.
Transmission is a CTN code 02A from a TDI Passat... Nothing changed other than a rebuild and an LSD. Injectors are big honking 0.260 HFLOX. I have a large FMIC, decently free flowing exhaust (though it still has a muffler)... I have my pump set up to keep smoke to a minimum but she'll still blow black if I load it up before the turbo is ready and there's a decent haze behind me at full load.

I was 5.2L/100km on a trip mostly involving secondary highways across Washington state and BC - lots of mountain passes. 5.8L/100km on my last run to Portland and back on the I5 mostly 5-10 over the speed limit.

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Title: Re: Petra Passat
Post by: air-cooled or diesel on October 21, 2017, 11:00:16 am
it had slipped my mind you had a passat. so its the same engine as the jetta, 1z, or ahu. the tune is the same, engine management. is the gearing the same? as the mk3 jetta? just to ask w/o doing research, perhaps the trans case has some differences. other than that its your m-TDI conversion, and turbo, i forget bigger turbo? along with some mods, and your tune.
getting some info together on this subject. for one my mk3 jetta, as is well known, has fuel mileage from 40-42.x mpg, in which case i have no idea why the passat has better mileage(as stock), and your m-TDI is killing it. in the future i have some options for a conversion(s).
Title: Re: Petra Passat
Post by: vanbcguy on October 21, 2017, 02:13:40 pm
The engine itself is an AHU from a Jetta, but there's not really much left that makes it an AHU. Since mine is M-TDI there's no tune / engine management really. The injection pump handles everything fueling wise.

The head is still stock AHU. I have a Colt Stage 2 cam, ASV pistons (they're the same compression ratio and everything but they have a better setup for cooling the dome), Integrated Engineering rods... I can't really see any of that impacting FE much. The cam might help a little.

Turbo is definitely larger. Mine is a GTB1756VK which is a newer design than stock.

Really I think it comes down to having the car in overall good shape. Good alignment, wheel bearings have been done on all 4 corners, brakes are in good shape, I run legit summer tires in the summer... Tire inflation alone can knock you a few mpg either way.

I should add too that I don't get anything like those numbers driving around in town. Especially not if I'm romping on it a lot. Juiced up diesels like their fuel when you're pushing them hard.

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