Big turbo build- take two

[DougLoBue]

Mod list:

Suspension
KW Variant 3 coilovers
H&R front & rear sway bars
034 track density front strut mounts
Defcon front control arm inserts
PowerFlex front control arm bushings
MadMax lower rear multi-link
Kmac upper rear multi-link

Brakes
Hawk HP+ pads
Slotted rotors
ATE SuperBlue Fluid
Stainless lines

Drivetrain
Front Raxles
Spec billet steel 13 lbs. flywheel
Clutchnet red pressure plate
Clutchnet unsprung kevlar pucked disc
BFI stage 2 motor mount set
Powerflex polyurethane steering rack bushings
Diesel Geek Sigma 6 short shifter
B&M short shifter
Force Fed Engineering metal shift mount bushings

Interior
Hertz Hi-Energy 165K component speakers
Sundown Audio SD-10-D2
Audison LS 500.2
JL Audio 250/1
Kicker EQ
Belkin A2DP input
Apple iPod input
iPod touch 32gb
Modshack gadgeTT
ProSport premium: oil pressure, air/fuel & boost gauges
OSIR shift ring light
Euro headlight switch

Fueling
Eurodyne Maestro software
Wideband AWP conversion w/ VVT module
V8 S4 MAF
Injector Dynamics ID1000's
Aeromotive Adj. FPR
Fuelab 41402 pump
OBX fuel rail -6AN
Custom FFE under hood surge tank
Fragola fittings & braided lines
2.0T FSI coilpacks & NGK 7 irridium plugs (BKRE7EIX, Stock #2667)

Motor internals
IE Rods - 20mm pins/ACL bearings
JE Pistons - 81mm/8.5:1 CR
Eurospec main studs
ARP head studs
AEB head
Ferrea valves, springs, retainers

Forced induction
Precision 5857 - DBB/4" inlet/v-bands
Precision 650hp intercooler core
MadMax Evo DV
Tial MVS
OBX intake manifold
70mm throttle body
Boost Valve dual stage boost controller
Magnaflow stragiht through muffler
EuroJet 4" exhaust tip
Force Fed Engineering turbo kit:
-4" turbo inlet pipe
-2.5" intercooler piping
-Tubular exhaust manifold
-3" turbo back exhaust

Exterior
Verdict Motorsports antenna delete
Headlight reflector delete
smoked turn signals
badgeless 5 bar grille
shaved front bumper

Last night's progress- from empty engine bay to this in about 2 hours thanks to Greg & Vince:





Tonight:

[bklnstunt718]

i wanna come by asap! sit on a chair like a little kid... AND WATCH!!!!

[DougLoBue]

Haha Jaymo you know where to find me man! Not to worry we got the majority of the install on video but last nights work it ran out of space somewhere and I didn't notice.

I'll get a lot more photos up here this weekend of the work leading up to this.


Hey anybody mind helping me out? I cannot for the life of me remember which knock sensor goes on which side??

[631 Corrado]

getttin paid.... getting paid.

[Tempes_TT]

Yeeeah buddy! So excited to see some progress from you man!

ps. what short shifter kit/shift cable end links do you have?

[DougLoBue]

Thanks man!

I have:

Diesel Geek stigma 6 under the hood (comes with the cable ends)
Force Fed bushings on the mount
B&M short shifter (shift rod side)

It's super notchy and short

[Vdub 2.0]

looks great, what are your hp goals?

[PLAYED TT]

The teaser pics look a lot better on a computer. Its about time

[DougLoBue]

Hp goals-- I wanna go fast. Realisticly I want 450fwhp pump and 550fwhp e85. I've never dyno'd AWD so I don't know those numbers yet. Last year I made 410fwhp with a small port head, bad tune and pump gas.

Time to go finish this mechanically speaking. Eurodyne support is trying to help me out reading my ECU but all efforts on my part keep failing. I hate this cars communication system- I even ran a wire straight from the ECU to my OBD2 port and zero luck.

[PLAYED TT]

Good luck Doug. Keep us updated.

[DougLoBue]

Well finishing off today all the mechanics are together. Due to the new intake manifold putting the TB in a different location than stock I'll need new piping so I decided to change it up entirely. Going to change to a passenger side throttle body I'm pretty sure. Will mean shorter piping and less heat soak in comparison to the last setup.

Motors all together... missing IC piping and a catch can and obviously wiring:



Cars on the ground:




Need to order some items for the fuel system. I picked up an adjustable regulator but I'm going to return all that garbage- keeping it stock with the RMR FPR drop in to -6an.

Also the ongoing saga of being unable to flash my car continues. I'm going to see if a dealer can bench flash it just to get me up and running then I can troubleshoot from there.

[jwalker1.8]

hmmm, curious how this leads to less heat soak...please explain

[DougLoBue]

hmmm, curious how this leads to less heat soak...please explain

My old IC piping setup literally ran from the turbo to under the exhaust manifold and wrapped around the passenger side of my car. The new idea I have for a setup won't run under the exhaust manifold and will be maybe 2 feet shorter.

Old setup:

[jwalker1.8]

yes, old setup was recipe for heat...

[DougLoBue]

New part for the day. I don't want to deal with an adjustable FPR.



Going out to install this and try to figure the ECU communication situation out-- total nightmare. About to buy a TT with a stock wideband

[631 Corrado]

your welcome.lol. (12pk) i told you that **** was dope

[l88m22vette]

Going out to install this and try to figure the ECU communication situation out-- total nightmare. About to buy a TT with a stock wideband

How far have you gotten?

[DougLoBue]

Here's the deal...

I have a 2001 AMU TT, stock NB 02

Last year I did a WB swap by using an OEM mk4 harness and unpinning the 02 wires and re-connecting them to my stock harness. I also removed my SAI relay and MAF sensor wiring. My car was running Unitronic at the time off a mk4 AWP WB ECU and the ECU was mailed to them to be flashed. When revisions were made my ECU was installed in a later model mk4 VW because my car could not read or flash the ECU. I had no problem running Vag-Com though.

Though this time I always had this code, car ran great just couldn't flash the ECU:

18058 - Powertrain Data Bus: Missing Message from Instrument Cluster
P1650 - 35-00 - -

People say this comes when swapping from NB to WB. I'm starting to think the ECU's communicate differently. Digging into AWP vs. AMU wiring diagrams I have found that the AWP has the CAN-BUS connected to the Instrument Cluster specifically the Green connector pin's 18 & 19. The AWP maintains the K line also though- which is the single wire old school diagnostic communications system.

On my AMU car I have found the CAN lines to run from the ECU,AWD,ABS and possibly other locations but not to the cluster. I decided to install pins and twisted CANBUS wiring from the cluster to the existing CANBUS circuit and I still receive the same code.

Still can't read the ECU with Eurodyne Flash but I can vag-com it no problem.

I will be digging through the wiring diagrams and comparing the CANBUS more extensivly. I did read a huge article today that describes most CANBUS communications to have a control unit. I don't know if 2003 VW setups are so old school that they don't have this.

http://marco.guardigli.it/2010/10/hacking-your-car.html

I haven't attempted to run wires to the OBD2 port yet for can-bus. After a beer I'll go out and try that one next.

[DougLoBue]

ECU update:

A couple of days ago I headed down to FFE and tried my ECU & cable read on a MK4 VW- I had the exact same results. Shipped both to Chris @ Eurodyne and hopefully it's an issue with the ECU that can be resolved. If not I'll buy another.

[PLAYED TT]

I'm glad your finally willing to scrap that damn ecu.

[20v master]

So why was an adj. FPR an issue?

[The_RoadWarrior]

^^^ I'm curious too ^^^

[DougLoBue]

I wasn't interested in having another adjustment. I'll be running 3bar and the stock FPR seems reliable enough.

I would have spent $300 on an adjustable and all the crap that comes with it just to have set it to 3bar or $70 to use the stock FPR and it came with most of the fittings I'll need.

[20v master]

I wasn't interested in having another adjustment. I'll be running 3bar and the stock FPR seems reliable enough.

I would have spent $300 on an adjustable and all the crap that comes with it just to have set it to 3bar or $70 to use the stock FPR and it came with most of the fittings I'll need.

Put a gauge on that OEM FPR and you'll see that they aren't very precise, aka it won't be right @ 43.5 psi.

[DougLoBue]

How off have you seen them be?

[MKllllvr28]

Mine's off by 4 psi. I run the rmr adapter.

[DougLoBue]

So an interesting event occurred today:

I shipped the ECU out from my job to Eurodyne in Canada. My company provides nuclear power products internationally and government defense products to the US. Canadian customs rang up my boss today asking why they were receiving a package for Eurodyne with an invoice for a nuclear valve going to Korea. Seems like paperwork got mixed up and I've become the start of a running office joke.

Guess my Canadian bound packages I'll pay full price for in the future...

[J Patterson]

So an interesting event occurred today:

I shipped the ECU out from my job to Eurodyne in Canada. My company provides nuclear power products internationally and government defense products to the US. Canadian customs rang up my boss today asking why they were receiving a package for Eurodyne with an invoice for a nuclear valve going to Korea. Seems like paperwork got mixed up and I've become the start of a running office joke.

Guess my Canadian bound packages I'll pay full price for in the future...

[PLAYED TT]

So an interesting event occurred today:

I shipped the ECU out from my job to Eurodyne in Canada. My company provides nuclear power products internationally and government defense products to the US. Canadian customs rang up my boss today asking why they were receiving a package for Eurodyne with an invoice for a nuclear valve going to Korea. Seems like paperwork got mixed up and I've become the start of a running office joke.

Guess my Canadian bound packages I'll pay full price for in the future...

Oh boy haha. That must have been a fun time explaining that one to the customs

[MKllllvr28]

Sounds like terrorism to me....

[DougLoBue]

haha yea it was an adventure. Still hasn't made it there yet even though it was schedueled for delivery today.

Today got another cluster in the mail. My old one's gas gauge didn't work and it was really super special in the winter- wouldn't function for about 5 minutes. Just crossed my mind how do I change the milage amount on the cluster?

Aside from this ordered some other toys for inside the car including an A2DP setup.

[DougLoBue]

While the ECU is out here's some photos from the motor work from a few months back.

ARP Main studs and IE rods






JE Pistons and fresh walls and decked block









AEB head, dipped, decked, new valve guides and seats cut

[DougLoBue]

Cable and ECU are on their way back to me!

ECU checks out, cable needed some repair- a big thanks goes out to Eurodyne's Chris Tapp

Now to try and squeeze my car into Force Fed for some intercooler piping and hopefully after that I can finally drive this thing...

[PLAYED TT]

Then after that I will definately drive this thing...and love every second of it

FTFY

[RabbitGTDguy]

Cable and ECU are on their way back to me!

ECU checks out, cable needed some repair- a big thanks goes out to Eurodyne's Chris Tapp

Now to try and squeeze my car into Force Fed for some intercooler piping and hopefully after that I can finally drive this thing...

Lookin good! Can't wait to hear how it goes!

Joe