Ultimate TDI tuning list

A

Audiobull

A2OC Donor
Right the time has come to start thinking about the track build so i could do with some serious suggestions for the tuning.
I so far still do not have a tdi a2 so that is at the top of the list. i have a petrol a2 but that is going to sit in the workshop under a sheet for ever now.

So far i have race cams coming,
custom made exhaust manifold for bigger turbo coming. I will be looking at the standard 1.9 turbo (same as in my caddy) or the darkside developements upgrade if there is any difference in the 2?

I need advice on intake, injectors and anything i should be looking at in regards to things such pistons, bearings while i am rebuilding the engine.

if its to be a 75 will i need to still have a back pressure problem that i have been reading about on the exhaust or will that be thrown out the window with the larger turbo?

Something that does need to be thought about is the amount of smoke. although it will be purely track i cannot be seen to be making a mess or making the track dangerous to others :rolleyes:
I know its not built for the track but thats why i want to make one :D
 
I actually enquired about this with two friends who work in the BTCC....bigger turbo,injectors,manifold and tube work to suit which can luckily do myself.Re map to suit set up,longlivity i dont know but would be fun to drive,stripped out...power to weight would be good,i have already a 1.9 turbo off a passat 130pd engine and the injectors.But to be honest expensive project and probably end up blowing the little 3 pot up..
 
How would you fit a roll cage to an A2? A friend of mine was thinking about rallying one, but the rules stated the roll cage must be welded to the body. This seemed to be a problem.
 
The 1.4 Tdi is more or less 3/4 of a 1.9 TDi Golf engine so there should be plenty of tuning info around which you can utilise. I'm sure Darkside where you bought your goodies from would give you some guidance but a reliable 150 - 170 BHP should be possible. (Heavy duty conrods and bolt sets etc are available but may not be needed for this power level.)

Things worth investigating - Golf PD 130 or PD 150 injectors, The A2 has 3 headgasket thickness options so try the thickest one (assuming it's not already fitted), a larger aftercooler, Golf variable vane turbo with the N75 valve programmed to work the vane actuator - this may help control black smoke as the fuelling will be trimmed until the turbo is producing adequate boost, gearbox checked / rebuilt with the reamed bolt mod for the diff (to replace the unreliable rivets)

Cheers Spike
 
I have found a bit of info regarding the tuning and there is plenty of help out there but as it is an a2 and there is nothing on the forum i thought i would start by asking here but looking at the replys about negative reliability problems, how expensive it might be and how a roll cage wont be fitted i can see why there is nothing on the a2 forums about it. Its a track car not a rally car. its a track car, there not reliable, its a track car they are never cheap!

as for those who gave a positive reply thank you, yes darkside are giving me plenty of help but i really was hoping we had some members who had already done it. i am going to turn to a tdi forums rather then here for this topic. hmm i did not think of variable vane that has pretty much solved most of the smoke problems. Interesting about the gaskets if its not got the thicker one i could lower cr a bit. i wonder if the 90's have the thicker one.
 
The different head gasket thicknesses are used to compensate for production tolerances on conrod length, crank throw, cyl block deck height and piston bump height so the 'design' CR can be achieved during engine build. I've just checked the gasket thicknesses and they are 1.45, 1.53 and 1.62mm so there would only be a small change in CR between each gasket.
If the high performance cam has more valve overlap than standard, this can reduce the effective CR as some of the incoming charge air flows down the exhaust port for a short period until the exhaust valve fully closes.
If you have not already seen it, Darkside have an injector table showing the potential of different flow rates against BHP - http://www.darksidedevelopments.co....jector-nozzles-for-1-9-2-0-8v-pd-engines.html
My guess is that our 3 pot diesels will be more reliable than a 4 cyl equivalent as the engine block and crank are stiffer due to the shorter length.
On roll cages, only specific motorsport disciplines mandate welded cages for competition use. I don't see any such rules applying to track day cars.

Someone has to be the pioneer on these projects and you seem to have put a fair bit of thought into it and are quite realistic about the build and running of an A2 track car so keep up the good work and let us all know how things progress.

Cheers Spike
 
Thanks spike your always on the ball with your replies its much appreciated.
I had not spotted the injector table so thanks for that i will have a good nosey in a min.

Yes i cannot remember ever seeing a car roll on track especially the track days i will be going to. its no competition, it will purely be just for fun. I have had plenty of track day cars but nothing so light so it should be fun especially when its slammed and widened. I do not mind testing the spaceframe if it comes to it on the roof.

I think they do have overlap, i will look further into that and find out the timings if not for the thread for me.
hmm i was thinking the thickness would be a little more between them. Not sure why i was thinking that.

I will make a project thread once things get moving and i have some good plans and info.
 
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