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    Thread: MK4 Jetta Wagon 16vT build

    1. Member elRey's Avatar
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      16vt 2.0L MK4 Jetta Wagon | B6 A4 Avant
      05-18-2009 02:06 PM #71
      Drove the car to SOWO and on the MT. run Sun morning. Car rode great. I have the wastegate adjusted open, so I'm only making 5psi up top. And I have timing pulled back ~6* via unisettings on stock 2.0L AZG management. Just breaking it in.

      Finally mock-up to clean and tighten everything before finally assembling it on the car.


      Turbo, manifold, and DP on car:



      Modified by elRey at 2:10 PM 5-18-2009


    2. Member elRey's Avatar
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      05-20-2009 12:02 PM #72
      Just a running update....

      I've been running ~7psi up top and car runs fine (not ideal) on stock 2.0L AZG managament with VR6 MAF housing and 1.8T 317cc injectors.
      I have unisettings @
      Primary fuel -> ~ -15%
      Ign offset -> ~ -6*

      Did some logs and trims are 0.8% and 1.6%
      The most timing pull I see is 5.3* and that's randomly stepping on throttle a little from cruise. During a run I see maybe 4* up top.

      Inj. duty peaks @ 63%

      I only wish I could get a true MAF reading. Anyone know a somewhat accurate calculation on for a VR6 MAF vs 1.8T/2.0L MAF housing reading? I know the VR reads 34% less air, but I don't think that dividing the MAF value by .66 is accurate. Anyone?


    3. Member GTrabbIt's Avatar
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      05-28-2009 02:42 PM #73
      Quote, originally posted by elRey »
      I know the VR reads 34% less air, but I don't think that dividing the MAF value by .66 is accurate. Anyone?

      I don't have any idea, but you would multiply by .66, not divide.

      either way, AWESOME build!! just read through both builds, great work!

      Our mk6

      oldskoolvw.com

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    4. Member elRey's Avatar
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      05-28-2009 08:29 PM #74
      Quote, originally posted by GTrabbIt »
      either way, AWESOME build!! just read through both builds, great work!

      Thank you.

      Quote, originally posted by GTrabbIt »
      but you would multiply by .66, not divide.

      Are you sure about that? If VR housing reads 34% (smaller value) less air and then I multiply that value by .66 I get an even smaller value.

      If 100g/s is the actual amount. VR reads 66g/s (34% less). 66g/s * 0.66 = 44g/s
      but
      66g/s / 0.66 = 100g/s


      Thanks for looking.


    5. Senior Member MFZERO's Avatar
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      06-01-2009 02:51 PM #75
      you are one crazy dude! congrats on making a sweet build sick!

    6. 06-02-2009 08:06 PM #76
      in N/A form, would this swap work with the stock ecu on a DBW? my engine code is BEV

    7. Member
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      06-02-2009 08:25 PM #77
      Congrats on the build, but please do yourself a favor and buy a turbo that's reliable, i'd have to see you on the side of the road with such a nice build.

    8. 06-03-2009 07:43 AM #78
      Awesome Build!

    9. Member GTrabbIt's Avatar
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      06-03-2009 09:43 AM #79
      Quote, originally posted by elRey »

      Are you sure about that? If VR housing reads 34% (smaller value) less air and then I multiply that value by .66 I get an even smaller value.

      If 100g/s is the actual amount. VR reads 66g/s (34% less). 66g/s * 0.66 = 44g/s
      but
      66g/s / 0.66 = 100g/s


      Thanks for looking.

      sorry, I thought you were trying to get from 16V to VR, then yeah, if you're trying to see what it would be from your current reading, just divide

      now back to your regularly scheduled program

      Our mk6

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    10. Member 18T_BT's Avatar
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      06-03-2009 09:21 PM #80
      nice...you can put in a 2.0 maf and run logs for g/s, then plug the vr6 one in and get a reading, right? what sensor are you using?

    11. Member elRey's Avatar
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      06-10-2009 11:25 PM #81
      Thanks for the kind words ppl!


      Quote, originally posted by 18T_BT »
      nice...you can put in a 2.0 maf and run logs for g/s, then plug the vr6 one in and get a reading, right? what sensor are you using?

      I could, but it would be hard to know how to match stock MAF reading to VR MAF readings. Ingitino angle and other variables need to be considered, not just RPM and throttle angle.


      UPDATE
      played with the wiring a little and now the wagon's running with a 1.8T ECU. Still 2.0L harness, just added wires for MAP, IAT, N74, N259, J299, and VVT solenoid.

      Spent the past hour adjusting things on the road with unisettings.


    12. Member sgolf2000's Avatar
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      06-11-2009 01:26 AM #82
      any codes with the 1.8t ecu? did you just have to wire from the sensors back to the ecu?
      f.s. mk4 avh complete head, intake and exhaust manifolds http://forums.vwvortex.com/showthrea...haust-manifold

    13. Member elRey's Avatar
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      06-11-2009 09:07 AM #83
      Quote, originally posted by sgolf2000 »
      any codes with the 1.8t ecu? did you just have to wire from the sensors back to the ecu?

      codes:
      16396 - Bank 1: Camshaft A (Intake): Advance Setpoint not Reached (Over-Retarded)
      P0012 - 35-00 - - expected since I do not have VVT

      17964 - Charge Pressure Control: Negative Deviation
      P1556 - 35-00 - - I don't have N75 controlling WG and T3/T0e4 is only set at 7 psi and it can't boost as fast as K03s

      That's it so far.

      And yes, wired from ECU to sensors. It really helps to have extra harnesses. Even just cut/partial harness from ECU connectors. I just removed pins from junk ECU connectors, insert then into my stock connector, and then spliced on needed connectors. I have the VVT, N75(WG), and N249(DV) solenoid valves electrically connected, but not controlling anything. And I put a resistor in for the J299 SAI relay. The only sensors I'm using that I had to added wiring for are the IAT and MAP.


      Also:

      I was also getting open ignition circuit for all 4 cylinders but no misfires. With 10 mins for searching I found VW issued a TSB #0402 ELECTRICAL SYSTEM that requires an ignition overlay haness on 01-02 2.0Ls. All it does is replace pin #1 on the coil to a direct ground under battery. So, I also replace pin #1 and just run it 6" to a bolt hole on the head and grounded it there. No more open ignition circuit codes.



      Modified by elRey at 9:15 AM 6-11-2009


    14. Member elRey's Avatar
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      16vt 2.0L MK4 Jetta Wagon | B6 A4 Avant
      06-19-2009 01:52 PM #84
      I little update. I'm now running a stock 1.8T AWP ECU @ 13psi. I was running out of injector at well over 95% duty @ 5500 RPM on gas, not even on E85 which was above 105% @ 5500 RPM.

      First problem I've run into though once I up'ed the boost from 6-7 psi to 13 psi was a misfire on #1 cyl under any moderate load. I swapped coils and found it to be the coil pack. I stole the coil from my MK2 and misfire was fixed.

      Plug looked fine to me.

      So, I've put in 630cc injectors with a VR MAF housing to handle E85 and gas.

      cool down to install the injectors

      Thanks to Clay@CTS for getting the injectors to me in 3 days

      4bar FPR and stock 1.8T 317cc injectors out

      stock 1.8T 317cc injectors with USRT extentions (anti-spacers)

      317cc vs 630cc

      swapping stock 1.8T MAF housing (2.375" ID / 2.75" OD) with VR MAF (2.75" ID / 3.00" OD)


      Cleared trims and adjusted fuel to -25% (as far as I could) via unisettings. I also pulled ~6* timing out to account for the lower calculated load due to the bigger MAF. After running my trims are +0.9* and -7*

      I haven't calucated inj. duty yet but looking at the vag-scope while driving it's way down below 80% (again on gas). Once I finish this tank of gas, I'll go back on E85. Only reason I went back to gas was I couldn't wait to turn up the boost from 6psi which I couldn't with E85 @ 105%+ duty.


      Modified by elRey at 3:31 PM 6-19-2009


    15. Banner Advertiser CTS Turbo's Avatar
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      06-19-2009 08:10 PM #85
      Looks good rey, is that TT225 charge piping on the pass side?

    16. Member elRey's Avatar
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      06-19-2009 10:09 PM #86
      Quote, originally posted by Clay @ CTS Turbo »
      Looks good rey, is that TT225 charge piping on the pass side?

      It is.... or what's left of one


    17. Banner Advertiser CTS Turbo's Avatar
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      06-20-2009 11:30 AM #87
      Quote, originally posted by elRey »

      It is.... or what's left of one

      Sweet man, looks great


    18. Member elRey's Avatar
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      06-21-2009 01:05 AM #88

      I tried dialing in more boost (14-15psi up from 12-13) and hit limp mode. Then I went and picked up some diodes. Vag-com now sees 10psi max for actual while boost gauge reads 15psi before I let off. However, I started to misfire again so I cut testing/tweaking short. I hope I just have to regap a plug or two. They are current gapped at ~.0295"


      Modified by elRey at 1:10 AM 6-21-2009


    19. Member duke_seb's Avatar
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      08-01-2009 05:25 PM #89
      what pistons are you running for this?
      :bow Old Vortex

      Quote Originally Posted by zukiphile View Post
      Really Volvo? A failure of system that is supposed to save the inattentive would have been noticed by a real inattentive driver?
      Really?

    20. Member elRey's Avatar
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      08-03-2009 12:06 AM #90
      Quote, originally posted by duke_seb »
      what pistons are you running for this?

      stock 9A 16v pistons and rods


    21. Member LOW36's Avatar
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      08-03-2009 03:50 PM #91
      You have an IM.
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    22. Member SpoolinJetta18T's Avatar
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      08-04-2009 09:21 AM #92
      MORE PLZ MORE!!!!!!!!!!

    23. Member elRey's Avatar
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      08-06-2009 03:37 PM #93
      Looks like I'm maxing out 630cc @ 3bar and 17psi. I'm logging 88% inj. duty @ 5700 RPM.

      I don't know if I can run a 4bar fpr and be able to switch back and forth from 93oct and E85 like I can now.


    24. Member elRey's Avatar
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      09-29-2009 12:50 PM #94
      nothing new. working on a homemade sEBC.

    25. 10-12-2009 12:50 AM #95
      Did you dyno it yet

    26. Member SlammedGolfIII's Avatar
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      10-12-2009 07:35 AM #96
      Sweet build!
      Quote Originally Posted by SlammedGolfIII View Post
      If it makes a difference, I really do miss my g60 Love my VRT to death but I wish I had the g60 also.......Thinking about building another one for my fiance for next year
      Quote Originally Posted by dogger View Post
      Your fiance should break up with you if you give her a G60. That's like giving her a cubic zirconia for a engagement ring...
      N.E.R.D.

    27. Member elRey's Avatar
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      10-16-2009 01:41 PM #97
      No dyno yet. My coils are fine for the street, but once on a dyno where the engine sees more load than on the street, I get misfires. I may try again in the next couple of weeks.


      Thanks!


    28. Member duke_seb's Avatar
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      11-06-2009 02:02 PM #98
      hey rey.... i have the motor together can you help with the cam gear?

      apparently I need a 1.8T ones out of a later model?

      also what tensioner am i supposed to be using it appears that the 16V one sits in to far did you use it and then space it out with the 1.8T cam?

      :bow Old Vortex

      Quote Originally Posted by zukiphile View Post
      Really Volvo? A failure of system that is supposed to save the inattentive would have been noticed by a real inattentive driver?
      Really?

    29. Member elRey's Avatar
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      11-06-2009 04:39 PM #99
      later 1.8T cam gear and for the tensioner either a mechanical 1.8T tensioner (which is nothing more than a spaced out 16v tensioner) or the mk4 2.0L tensioner (what I used, but not recommended). If you use the 2.0L one, don't pay attention to the arrow. Just tighten it until the belt feels right after you've ran the engine. This will end up being way tighter than the indicator arrow on the 2.0L tensioner was designed for.

      You may need to swap out the stud that's in the head to match which tensioner you use.


      Modified by elRey at 4:40 PM 11-6-2009


    30. Member duke_seb's Avatar
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      11-06-2009 09:44 PM #100
      when you say spaced out tensioner how do you mean?.... should i just put a washer or something behind the 16V one and then use that?

      I already figured on the stud after lining up the tensioner with the belt it was almost off the stud

      another thing i noticed today was that I need to space out the coil pack otherwise it hits the intake.....bummer

      got lots of stuff done in the last few days.... got some pictures up in my thread

      :bow Old Vortex

      Quote Originally Posted by zukiphile View Post
      Really Volvo? A failure of system that is supposed to save the inattentive would have been noticed by a real inattentive driver?
      Really?

    31. Member syracusegli's Avatar
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      11-08-2009 09:25 AM #101
      wow, this is awesome. Very nice work
      Quote Originally Posted by 2mAn View Post
      go crash into a hybrid
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      IG- Roguemetal

    32. 11-08-2009 06:12 PM #102
      I am trying to figure out if you ended up deleting out the distributor and doing a small cam position sensor. There are not many pictures favoring that side of the engine

    33. Member elRey's Avatar
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      11-08-2009 09:10 PM #103
      check the link to the head swap in the first post. I go over it there.

    34. Member raymondlee's Avatar
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      11-20-2009 07:25 PM #104
      i want to do this.

      Can this be done with stock mk4 pistons and a head spacer from c2?


    35. Member elRey's Avatar
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      11-20-2009 10:54 PM #105
      Quote, originally posted by raymondlee »
      i want to do this.

      Can this be done with stock mk4 pistons and a head spacer from c2?

      It shouldn't be any different than clearance issues ABA/16v ppl have to deal with. Search for ABA/16v swaps using stock ABA pistons.


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