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Diesel Perf: 1.9 Litre T.D.I. Volkswagen Beetle

harrysmith500

harrysmith500

Well-known member
Lifetime Membership
I have a 1998 VW Beetle, equipped with a 1.9 Liter Turbo Direct Injection diesel motor. Stock it has 85 horse power. I am going to fabricate an air intake system utilizing a K & N type air filter, it will be a short ram in the effort of doing it economically. I should gain about 1-2 horse power with that, and about an additional 3 horse power with the mufflers and cat's removed (my rough conservative guess).

So by freeing up the power that is there, I would be sitting at a bare minimum of 90 horse power.

Now the next question is, Programmer?

The Bully Dog programmer is 550$ and will give me an additional 25 horse power (Claimed), or BD has one for 400$ that will be between 15-20 horse power. I would like to stick with Bully Dog as they sponsor some things I like to support.

Tell me what you guys think and how wrong I am on some of the stuff I have said. Or tell me if buying a programmer is a waste of money....because it might be.




Bully Dog Chip
http://bullydog.com/product/index/product_detail/180



Since this picture I have tinted the windows.

photo.jpg
 
Last edited:
Intake is cheap

I bought the K & N filter for 10 bucks, and I have a welding shop to build the intake, so I am mostly doing it so I can hear the turbo work...... I like turbos.
 
Wow...

you are my hero!! That is so cool!!!

What programmer did you put in your car?
I imagine the one from the Portland company?
 
Forget Bully Dog, etc.


Go to http://www.tdiclub.com

A K&N really doesn't add any power to the TDI. The stock intake/filter breathes perfectly fine. Until you go stage III you really don't need to touch that.

Get a Kerma Tune @ http://www.kermatdi.com

They mail your a Q-loader and then you can get customized and updated tune file via E-mail:
http://www.kermatdi.com/servlet/-strse-ECU-Tuning/Categories


BTW... I am 99% sure you car is 90 HP stock.
Muffler is a common modification on that motor but it doesn't really give you much HP or TQ, same with the cat. You will see gains there when you go with a larger turbo and more agressive tuning/ECU. You can spend the money on the exhaust but don't expect much.

If it were me (I also have a TDI (2005 PD)). I would obviously make sure you are up to date on your preventive maintenance. How many miles do you have? I think in 1998 they had a 60,000 mile timing job due. If you get the updated belt all future timing jobs can be done with 100k in between. Make sure you replace the tensionor, water pump (usually the problem) and all associated stretch bolts. MAKE YOUR MECHANIC GIVE YOU THE OLD BOLTS!!! I have heard of motors/transmissions falling out of these cars from mechanics NOT replacing these bolts. Also make sure you intake manifold is cleaned out. They used to get plugged pretty easily.

AFter you get that done, I would
-get a Kerma Q-loader tune
-Remove the muffler (straight pipe)
-Devils Own Meth/water injection (once you get that have Kerma update your tune)
-Omi/Old man intake... Kind of a custom intake between the air filter and turbo


From here you can either leave it be or start looking at larger turbo, full exhaust, etc. But where do you stop?

Really... spend a lot of time at TDICLUB.COM you will learn a lot there.
 
sweet!!!

thanks for the info.... I am doing the exhaust and intake because I can do it for free, because we have a trucking company and I just use our shop and what not... it keeps me entertained.... I just want some quick power, don't wanna go crazy with a different turbo or anything like that..

It has 125K miles........ we actually have 2 of them, my older sister drives one.

your right on the 90 HP, i don't know why I was thinking 85...
 
harrysmith500 said:
thanks for the info.... I am doing the exhaust and intake because I can do it for free, because we have a trucking company and I just use our shop and what not... it keeps me entertained.... I just want some quick power, don't wanna go crazy with a different turbo or anything like that..

It has 125K miles........ we actually have 2 of them, my older sister drives one.

your right on the 90 HP, i don't know why I was thinking 85...
Click to expand...

shes just started to get broke in. look into bigger injectors etc... easy power
 
Yes... Larger injectors are a must for that motor, I forgot about that. The TDI I have (PD) injectors are about $400 a piece (x4), don't help until you get a larger turbo and a major ***** to replace. On the 1998-2003 motors they are very easy to replace, cheap and help out a lot.

If you have the cheap and easy means to do an exhaust, then go for it, but don't expect a lot. You will get some better throttle response.
 
yeah'll i'll do the exhaust and intake just so i can hear the motor work.. i love that sound.

question?

What does PD stand for???

hooking up with kerma tuning out of salt lake, he is on the TDI club.

check his web site.http://www.kermatdi.com

what do you think?
 
harrysmith500 said:
yeah'll i'll do the exhaust and intake just so i can hear the motor work.. i love that sound.

question?

What does PD stand for???

hooking up with kerma tuning out of salt lake, he is on the TDI club.

check his web site.http://www.kermatdi.com

what do you think?
Click to expand...


I already recommended Kerma TDI to you! ;):beer;
I believe he is actually in Toole. They also have a shop in the Vail Valley, CO.

PD like mentioned after your post is "Pumpe Düse". It is ONE of their injection systems. It is not on your car. It is on the 2004-2006 MK IV TDI's and the 2006-2007 MK V TDI's. It uses an extremely high pressure injection system. The injection/injectors are controlled by and extra lobe on the cam shaft. It injects/atomizes fuel at something like 85,000 PSI. It is a nice idea, and works well, but there are some question about how long the cam shaft an tappits will last because of those extreme pressures.

There is TONS of info on the system if you are really interested at TDI Club.


The TDI Rally/racing car has a HUGE VNT22 hybrid or something similar under the car. Euro intake, huge injectors, etc, etc.
 
www.vwvortex.com has all your answers, guys on there with far more power than a TDi rally car. Oh and there is still tons of guys asking what oil to use, what blinker buld are best etc. etc. you'll feel right at home. Best part is alot of guys from europe who have been modding diesels before anyone over here turned up a diesel pickup.
 
ElectroTech said:
www.vwvortex.com has all your answers, guys on there with far more power than a TDi rally car. Oh and there is still tons of guys asking what oil to use, what blinker buld are best etc. etc. you'll feel right at home. Best part is alot of guys from europe who have been modding diesels before anyone over here turned up a diesel pickup.
Click to expand...

:rolleyes:

Wrong... that is the place to go for VW/Audi gas motors but the complete wrong place to go for VW/Audi Diesel motors. Go to the Diesel forum there and almost everyone that asks a question is referred to TDICLUB.COM

The "Tex" (as it is known) has a lot of good gas info and good general car info (their fabrication forum is a good read) but with that site comes a LOT (TONS) of bull$hit. Lots of people that should not be giving advice. When you find out who knows what they are talking about, there is some great info available.


I just hit 100,000 miles on my 2005 last week (averaging about 3700 miles per month). I am basically stock. I have added a skid plate since the car is so low and I drive the Winter Colorado roads, a frostheater which heats the coolant at night (it actually end up heating the entire motor since the coolant flows everywhere), a Stanadyne FM-100 fuel filter management system (better filtration than the Mk IV VW system, MK V system is much better), and then tint and clear bra. After I do the 100k timing job I will more than likely chip the car with Kerma before March and then build my own exhaust.

Edit... I also have a Eurojet upgraded SMIC. The intercooler on these is kind of a joke, but no need to touch it until you at least chip. I had the dealer damage my OEM unit giving it a boost leak when they replaced a turbo under warranty @ 45k miles. They denied they damaged it and said the car had a front end impact which I did not report (complete lie). I was able to get a Eurojet Side mount intercooler for $325, which at the time was $300 cheaper than they s old for. You can get them now for about $500. I chose a Side mount intercooler over a front mount because I wanted to maintain the stock/OEM look and not carry the ricer boy racer image. A front mount also blocks the radiator, increasing coolant temps at times. I was also worried about gravel/sand/etc eventually destroying it on the winter roads.
 
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