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Tuning my Cupra TDI (PD150) - Remap, EGR, DPF and Mufflerectomy

Discussion in 'Motors' started by MrSix, Jun 23, 2011.

  1. Firestar_3x

    Caporegime

    Joined: Mar 11, 2005

    Posts: 29,216

    Location: Leafy Cheshire

    In the same vein you should have run it with no exhaust see how far that got you......
     
  2. TaKeN

    Capodecina

    Joined: Aug 18, 2005

    Posts: 13,040

    Location: Shropshire

    Always liked the Cupra TDi, might be my next purchase after seeing this ;)

    I've tuned my 306 HDi Mr Six, the backbox mod seems quite a common thing to get the backpressure off the turbo.

    My car is up from 90bhp to 150, which is a hell of a difference. Not sure how much it weighs compared to your Cupra.
     
  3. MrSix

    Soldato

    Joined: Oct 21, 2004

    Posts: 6,147

    Location: Los Angeles

    Not sure I'd fancy running my daily car with no exhaust ;)

    I am very pleased with the car and being able to squeeze extra power like this by making cheap and easy modifications adds to the pleasure. I'm sure I'll be beaming ear to ear once it's remapped :) Although I fear it's a slipperly slope that'll involve an Allards hard pipe kit, Sachs clutch and hybrid turbo in a few years.
     
  4. Firestar_3x

    Caporegime

    Joined: Mar 11, 2005

    Posts: 29,216

    Location: Leafy Cheshire

    My point is a total removal of all restriction isn't necessarily the best way to get the most power.

    How long does it take for your ECU to adapt to the increased amount of air it could suck in on the Dyno?
     
  5. MrSix

    Soldato

    Joined: Oct 21, 2004

    Posts: 6,147

    Location: Los Angeles

    So what are you saying then?

    And I have no idea - but we did multiple runs until we achieved a consistent figure.
     
  6. Matt82

    Capodecina

    Joined: Mar 13, 2004

    Posts: 16,548

    i told you the other day that your filter is actually larger than that fitted by audi to a B5 RS4, a filter wont make any difference but the airbox itself may lol

    ive actually seen cars LOOSE power on the dyno with nothing attached to a throttle body

    iether way, as long as you saved yourself from buying a stupid "performance filter" then whatever convinced you, you did the right thing
     
  7. Matt82

    Capodecina

    Joined: Mar 13, 2004

    Posts: 16,548

    still rofling at the no air box test

    read this

    http://www.clubgti.com/forum/showthread.php?t=199237

    Test 1, open throttle body, resulted in the in the worse torque curve and had peak bhp measurement of 142bhp@6200rpm

    Test 6, STD airbox, had improved torque range and resulted in 145bhp@6100rpm

    Test 12, Pipercross Pod filter, improved the torque range further and resulted in a peak of 148.5bhp@6500rpm

    My choice, Test 25, Modified air box and OE filter, improved torque even further than any of the other combinations and resulted in a peak power measurement of 151.2BHP@6200rpm
    lots of tests dont by some very clued up people
     
  8. TaKeN

    Capodecina

    Joined: Aug 18, 2005

    Posts: 13,040

    Location: Shropshire

    It's a slippery slope for sure :o

    I ended up fitting an intercooler, making up all my pipework, upgrading the brakes, de-catting the exhaust, replacing the backbox with a mongoose that needed adjustment to make it fit! , replacing the interior with GTi seats (door cards are the same) purchasing two different maps for the ecu, Buying a flashing tool to flash the ecu and then replacing the clutch!

    I did all the above myself at home here on the farm, Hybrid turbo and uprated clutch would be the next step along with fuel pump work, but I'm not slipping down that slope again :p
     
  9. MrSix

    Soldato

    Joined: Oct 21, 2004

    Posts: 6,147

    Location: Los Angeles

    hah! That's quite incredible tuning really from 90bhp to what? 170bhp at the end? How long until the internals need replacing after all that?
     
  10. TaKeN

    Capodecina

    Joined: Aug 18, 2005

    Posts: 13,040

    Location: Shropshire

    Forgot to mention I removed the EGR valve aswell and made up blanking plates for it!

    I'm running about 150bhp right now, I could run more, I'm using a stock OEM Sachs unit which is probably at it's limit right now. But it doesn't slip YET.

    People on the 306.net forums are running 165+ , but IMO it's just asking for trouble!! Not really sure how long the internals will last. One lad managed to get oil blowing past the rings so I'd consider that not good :p
     
  11. Relentless81

    Sgarrista

    Joined: May 18, 2010

    Posts: 9,591

    I'm sorry but in a thread about tuning diesels this made me do an LOL :D
     
  12. TaKeN

    Capodecina

    Joined: Aug 18, 2005

    Posts: 13,040

    Location: Shropshire

    OI! :p

    Tractor power for both farming and social purposes!!
     
  13. MrSix

    Soldato

    Joined: Oct 21, 2004

    Posts: 6,147

    Location: Los Angeles

    Just a brief update - the car is going in for remapping tomorrow now. Friday was cancelled because Pete at Thor came down with man flu, so rebooked for Tuesday.
    Currently sitting at 160bhp so would hope to see somewhere around 180-190bhp after a bit of software.

    Since having the exhaust off I've noticed an increase in MPG by an average of 8-10 on a run. I'm putting this down to the extra 10lbft torque which means that at 60-70mph the economy is much improved...town driving seems the same now.

    When I get my pit bike and trailer hooked up again it's also be interesting to see what I average on the way to the track. Before it was 48-50mpg with the majority of the journey towing at 70mph on the M6...I'm expecting now to see mid 50's hopefully.
     
  14. Matt82

    Capodecina

    Joined: Mar 13, 2004

    Posts: 16,548

    8-10mpg is pretty epic

    is that using the mfa figures or old fashoned calculator way?
     
  15. Dr Who

    Sgarrista

    Joined: Nov 11, 2004

    Posts: 8,023

    Location: Wiltshire

    Depends, if they are back to back then the differences are generally reliable :)
     
  16. MrSix

    Soldato

    Joined: Oct 21, 2004

    Posts: 6,147

    Location: Los Angeles

    Just using the on board average mpg readout - comparing before and after.
     
  17. Stormster

    Mobster

    Joined: Oct 18, 2002

    Posts: 4,672

    Location: Stoke-on-Trent

    So basically not particularly concrete at all.

    Use your calculator :) Will be transformed with the remap :)
     
  18. MrSix

    Soldato

    Joined: Oct 21, 2004

    Posts: 6,147

    Location: Los Angeles

    Jesus christ, some of the replies in this thread almost make me want to just forget posting up the results and keep it to myself.

    The dyno isn't accurate, the MPG isn't accurate, the moon wasn't aligned correctly when you did that run...blah blah blah.

    All of the results that I've documented have been 1:1 before and afters - measured using the same instruments with the same tolerances whilst maintaining every variable possible within my reasonable control.

    If that's not good enough for you then get out of my thread and ignore my findings.
     
  19. Stormster

    Mobster

    Joined: Oct 18, 2002

    Posts: 4,672

    Location: Stoke-on-Trent

    Keep it to yourself then, theres no need to moan - trust me I have a near identical car, you go and work out your MPG from your trip computer compared to what your calculator says.

    It WILL be different. But yes I see your point. Moaning aint cool though nor is being abrupt and rude :) Enjoy your remap.
     
  20. MrSix

    Soldato

    Joined: Oct 21, 2004

    Posts: 6,147

    Location: Los Angeles

    Glad you see my point and thank you I will enjoy my remap.