Jetta mkv TDI BKD build

**Jetta_MkV** · 06-02-2014, 11:35 AM

Yeah, my friend did a great job on the exhaust. He has a hoist in his backyard which made things much much easier. I requested something and he delivered 100%. You don't get that everyday, especially at some mechanics and aftermarket workshops. The exhaust took 15 hours to complete divided into a 3 day period (including breaks and mucking around). I'm getting my 3rd updated tune from Malonetuning in the next 2-3 days and I think i'll be running around 28-30psi. I think this tune will max out my nozzles. I would recommend Malonetuning to everyone, they are diesel experts. AFR is around 16-17:1 which is basically smokefree.

Your octavia looks pretty good, you did a great job!
Here is a brainstorming session for your new audi. Doesnt the audi have twin turbo? If so, you can connect 2 gtb2060vklr turbos on the v6 and you'll be flying. These turbos only come off the Mercedes E 350cdi blue efficiency 258hp. I think they only sell these models in Europe though.. could be wrong. I have a friend over in Germany that got one off the wreckers with 8000km on it and he welded the turbo onto the bkd manifold for me.

**gldgti** · 06-02-2014, 05:12 PM

Nah, the V6 2.5l TDI us a single turbo, despite what redbook (wrongbook!) and most clueless owners have to say

. Just the one turbo on these models, which is fine by me - less complexity!

Its also a pretty good size for the engine capacity, so even without changing turbo's its got some tuning potential. Best thing about the setup though is that the factory exhaust manifolds are lovely, so upgrading the single turbo is made that much easier.

**kaanage** · 07-02-2014, 06:41 AM

So no cat on this? I'd blank the plates in the pics.

I've seen one of the vendors on TDi Club running a VKLR without the water cooling but it's great that you got yours plumbed in. Will you be upping the nozzles?

I really have to get on to mine sometime - this thread may be the inspiration I need.

**Jetta_MkV** · 07-02-2014, 03:00 PM

Originally Posted by kaanage

So no cat on this? I'd blank the plates in the pics.

I've seen one of the vendors on TDi Club running a VKLR without the water cooling but it's great that you got yours plumbed in. Will you be upping the nozzles?

I really have to get on to mine sometime - this thread may be the inspiration I need.

I'm not an expert in cars but the Mercedes e350cdi blue efficiency uses water cooling for its main source of cooling for this specific turbo. Would you be referring to the 2260vk maybe? That doesn't use water cooling.

I just received my 3rd updated tune for my car.
Malone has done the following:
1. Increased the peak boost from 26psi to 28psi.
2. Increased fuelling to further increase power.
3. Extended boost and fuel at higher rpm so the power lasts longer before tapering off.

Yeah I'm going to upgrade the nozzles to the bosio race r1287's. They will get me to 300hp without much smoke.
Even if i run max boost that my turbo can support (around 35psi) i won't really "run out" of stock nozzles but there will be tons of smoke. This is because the stock injection duration is stretched very long, resulting in an inefficient fuel burn. Its not necessarily a lack of fuel, its just inefficient injection. This is why its better to upgrade the nozzles which i will be doing soon.

What have you done to your car?
If you are after the same turbo as me i can get you a great deal.

**kaanage** · 07-02-2014, 03:30 PM

I know about the VKLR and water cooling - it was added to protect the ball bearings - but this guy was running one with just the oil lines and mentioned how its temps were fine when someone specifically questioned him about the water lines not being connected.
He's a Malone dealer and I was planning to work with him if my current tuner wasn't up to tuning my updated engine.

I've got a 2056VK (same as in gldgti's Allroad, I think), a set of injectors with Firad +80 nozzles (really wanting to avoid the smoke and high EGTs from extended injection durations) and a SEAT intercooler in the shed waiting for an exhaust manifold and dump pipe (I'll get a high flow cat fitted to mine). Unfortunately, a Darkside exhaust manifold costs $$$ and they mucked up when shipping my injectors and intercooler so I got hit with a mega tax and duty bill

**Jetta_MkV** · 07-02-2014, 07:21 PM

Hmm well I'm not sure how long that turbo will last since Garrett says that watercooling improves mechanical durability and it lengthens the turbos life.

Yeah its good to avoid the smoke if you can. I'd stick with a cast manifold over a stainless one for a TDI engine, that's why my turbo got welded onto another stock cast manifold.

Testing out my new tune. It feels pretty good

Sent from my Nexus 7 using Tapatalk

**Jetta_MkV** · 25-02-2014, 09:07 AM

Does anyone have any recommendations on what thicker gear oil I can use in my jetta?

I was advised to do this from the clutch company because I am experiencing a lot of gear rattle and they said the noise will reduce if I go thicker gear oil. The SMF is very loud...

**OilBurna** · 25-02-2014, 01:11 PM

Very nice build so far I'm envious will be a real sleeper.. Where ate Malone based?

Sent from my iPhone using Tapatalk

**Jetta_MkV** · 25-02-2014, 02:33 PM

Originally Posted by OilBurna

Very nice build so far I'm envious will be a real sleeper.. Where ate Malone based?

Sent from my iPhone using Tapatalk

Thanks a lot. Yeah the project is going well. Nozzles should be coming very soon too.

Just got another updated tune with 30psi from Mark Malone. Malone is in Canada or America. He is very helpful and you won't be disappointed with his tune. I have had 4 tunes from him and never had an issue. The car makes over 220hp now and it still doesn't smoke.

Sent from my GT-I9505 using Tapatalk