Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...

[ryanp]

Hi

Thought I would finally post a build thread on this Forum. I figured you guys wouldn't want to see a dirty diesel on a GTI Forum, but seems like there are a fair few on here.

Back in March I bought a 2007 Jetta 2.0 TDI (BKD Engine). Here are some pics of it when I got it:






 
First up is the chassis -
 
Audi 18" x 8.5" Fat Fives with 225/40/18 Uniroyal Rainsports


 
KW V1 Inoxline

 
We also fitted an Audi TT 2.0 TFSI Rear Axle and Alloy Hubs that gave us 26mm more width and TT Front Alloy Hubs and Cast Wishbones, which give an extra 30mm and more camber. I have loads of pics, but didn't upload them. Everything is much beefier and lighter.
 
R32 345mm Front and 310mm Rear Discs. The front calipers have a TyrolSport Caliper Stiffening kit, which I would recommend it to anyone. Google it and see what I mean.

[ryanp]

We used Eos 3.2 FWD Splash Guards with fit perfectly with a slight modification

 
And it looked like this:




 
We then fitted a Darkside Developments EGR Delete and removed the EGR cooler completely:

After we mapped it and took it to the dyno, here were the results:

 
Some little interior mods -
 
Scirocco Flat Bottom MFSW


 
Passatt CC Switches

 
Thats how it stayed for a few weeks, but we had plenty more in the pipeline.

[ryanp]

We then concentrated on the body mods, we did the following:
 
Golf GTi Front bumper with Summer grills
Jetta GLI Rear Valance
Hella Projectors with Lamin-X Gun Smoke Tint and Osram Nightbreaker Bulbs
Smoked Rear Lights
Smoked Reflectors
Smoked Indicator Lenses
Smoked Numberplates
Rolled and Flared arches
Black VW Emblems
 
Here is how it looked:




 
Next was to fit the Darkside Developments 2.0 16v TDI Turbo kit with a GTB2260VK Turbo from a 3.0 v6 Audi:

 
Along with an S3 Intercooler and hard pipe kit (I didn't get a pic of the cooler before we fitted it, but it is all alloy with welded end tanks and no clip connectors):

 
Milltek 3" System (made for a US Jetta GLI):

 

 
We also modified the MAF, as it was deleted from the map:

 
Then we took it to the same dyno so see what we were making

 
235.3BHP and 330Ft/Lbs. This is on a very conservative dyno (the operator calls it the 'heartbreaker') with ZERO smoke and a very road friendly tune. 3 days after fitting the turbo I drove 1500 miles to, from and around Cornwall and averaged 57mpg for the whole trip. It didn't skip a beat.
We still have some adjustment in the stop screw to get the boost to come in a little earlier, but it still pulls very well from low RPMs. What you lose at the bottom end is nothing compared to what you gain at the top end, it pulls like crazy to the 5000rpm fuel cut we have in the tune and pulls 130mph in 5th easily. I have found the 140mph electronic limit though, which we are working on removing ASAP!

[ryanp]

Next on the agenda are a Sachs SRE Single Mass Flywheel and Sintered Paddle Clutch, Peloquin Limited Slip Differential, fitted to a low mileage PD170 Long Ratio Gearbox
 


 
Someone on the Edition 38 forum posted up a pic of the Jetta at their show:
 


We then fitted the Sachs SRE Single Mass Flywheel and Clutch and a PD170 Long Ratio Gearbox with a Peloquin LSD Installed. We also strengthened the shifter forks so we can do some fast changes. Once the clutch was run in, a set of Race PD Injectors was dropped in.

Here are the results from this afternoon:
 

 
We did 3 pulls and they were all pretty close together, the best run was 301hp and 440Ft/Lbs.
 

 
And here is a graph comparing the stock power to now, we have made pretty good progress!
 

 
Here is the spec we have now:
 
2.0 16v BKD PD140 Engine
Darkside GTB2260Vk Turbo Kit with Tubular Manifold and 3" Downpipe
Darkside Race PD Injectors
Darkside FMIC Kit with S3 Intercooler and Alloy Pipework
Darkside EGR Delete Race Pipe (Retaining ASV)
Milltek 3" Non-Resonated Exhaust System with Twin 76mm Jet Silencer
Darkside Developments Re-Map with MAF and EGR Delete
 
301BHP & 440Ft/Lbs – Dyno Proven
 
PD170 BMN Long Ratio Gearbox
Peloquin Limited Slip Differential
Sachs SRE Single Mass Flywheel with Sintered Paddle Clutch
Polyurethane Filled Dog Bone Bushes
Darkside Developments Short Shift and PU Filled End Links
 
R32 Front Brake Calipers
R32 345mm x 32mm Brake Discs
Genuine Audi S4 Front Pads
TyrolSport Caliper Stiffening kit
R32 Rear Calipers
R32 310mm x 20mm Rear Brake Disc
Genuine VW Rear Pads
Eos 3.2 FWD Rear Splash Guards
Silver Zinc Plated Calipers
 
KW V1 Inox Coilovers
Audi TT Front and Rear Top Mounts
Audi TT Alloy Front Wishbones with Solid Bushes and Adjustable Ball Joints
Audi TT Alloy Front Hubs and Alloy Track Rods (26mm Wider Track)
Subframe Spacer Kit
Audi TT Driveshafts
19mm Front ARB
Audi TT Rear Axle with Alloy hubs (30mm Wider Track)
Passat R36 21.7mmx3.6mm Rear Anti-Roll bar
 
Audi A8 ‘Fat 5’ 18”x8.5” ET45 Wheels
Uniroyal Rainsport 2 225/40/18 Tyres
Genuine VAG Wheel Bolt Caps
18" Spacesaver Spare
 
Hella Projectors with Lamin-X Gun Smoke Tint and Osram Nightbreaker Bulbs
Smoked Rear Lights
Smoked Reflectors
Jetta GLI Rear Valance
Rolled and Flared arches
Black VW Emblems
 
Leather Sports Seats
Scirocco R / Golf IV Multifunction Steering Wheel
Scirocco Headlight, Mirror and Window Switches
I-Pod Adapter in Armrest
 
Next step is a cam, headwork and bigger injectors. All of which are difficult to source, but I will find them!

Any questions, please don't hesitate to ask!
 
Thanks
 
Ry

[ryanp]

The results from GTI Festival at Santa Pod last year:



We had been down at Santa Pod all day today taking the Jetta up the strip. I managed to put in exactly 20 runs back to back without even a hiccup! All the runs had a terminal speed of over 100mph even when I selected reverse or had the odd missed gear!! As this was my first time out drag racing launching was the main issue so there are still a few tenths to gain and a less corner friendly suspension setting might help too but I’m happy as it’s exactly as it drives on the road!

The best run was a 13.8419 and the best terminal speed was 105.43mph. AFAIK the Fastest FWD TDI of the day.
We missed the fastest TDI trophy by 0.4 sec. That went to a nice guy with a homebrew Mk2 Golf Synchro/Haldex sporting a PD150 Lump, Hybrid Turbo and 150bhp shot of Nitrous!!

Here are two slips:


 


YouTube of the Jetta:

That was a 14.4 @ 103mph.

Hope you like it!

[Andy]

As said on the other forum--awesome car :notworthy:hopefully all been well,come next year i will be buying a darkside turbo for mine if my car behaves itself

[ryanp]

We took the Jetta to Shark Performance in Mansfield yesterday to an Open Dyno Session.

They use a BaPro Dyno so we thought it would be good to compare how the Jetta performed against the DynoDynamics we use on a regular basis.




301.2bhp and 440Ft/Lbs - DynoDynamics @ John Sleath
299.5bhp and 438Ft/Lbs – BaPro @ Shark Performance

Difference is ~0.5% overall so I would say our results are accurate :)

Cheers

Ry

[GTsport]

Seen this car on Darksides website - amazing stuff 

Absolutely love the Audi fat fives 

I shall be back later to have a proper read!


 

[ryanp]

 
Bit of an arty shot for you:

 
Big thanks to Adam and Tom at No Smoke, No Poke .com for the pictures. We will have a full company feature on their website when it is launched mid Feb.
 
We will also be attending the Charity Dyno Day / Car Show at Thor Racing in Coventry, it would be great if any of you guys could attend!
 
For the eagle eyed you will notice the Front Bumper has been painted as well as the rest of the bodywork, same colour as before but it looks like a completely different car! Also got some Audi S4 Avus Wheels in Hyper Black (thanks Metal Magic of Barnsley). We fitted the Jetta GLI Sideskirts as well.
Plans for the bodywork are the vehicle wrap the chrome around the windows (decided against painting it) and we will also fit a textured black from splitter as I think there is too much blue on the front now.
 
We put some SuperPro Console Bushes, set up for increased Castor and then took it to Russ at Mick Gardner Racing for setting up. All we can say it WOW, Russ is a genuis when it comes to setting up suspension, as well as being an Ohlins Suspension Dealer, he sets up cars for a lot of big name companies and race teams so knows his onions (theres a Spring Onions joke in there somewhere!). I would recommend anyone to go and see Russ if you want your car to handle how it should!!
 
We also have a complete new interior which should turn a few heads, its not 100% finished yet though, waiting on a fancy new gearknob from Germany and then that, the handbrake handle and armrest cover are going to MJ Interiors for a 'freshen up'. I will post up pics when it is finished.
We also have all the ingredients for some more power so keep your eyes peeled for some more updates!
 
Thanks
 
Ry

[Sunglasses Ron]

Sleeper.com  Great work 

[mortygttdi]

Just like to say if anyone has any worries about buying or having any work done by Scott and Ryan then don't they are the best set of lads at Darkside I have come across top lads

Darren

[Phil Miller]

Great stuff, so when my turbo goes bang i will be knocking on your door, great car mate

[Andy]

Cheers of the heads up Darron

[mortygttdi]

Still not been in the Jetta I always seem to go over when its raining

[Andy]

If you take the jetta out ,its a Good.test drive to my garage