VP37

TDI remap guide

or:takethelongwayhome bynexus665

Introduction
ThisisaguidetohelpunderstandhowtoproperlyremapaVEPTDIitsaworkinprogress,should youfindanyerrorsorwanttocontributesomething,pleasecontactmeviaPNat ecuconnections.commynicknameisnexus665. Forcompletenesssake,Iveoptedtoincludealotofthingsthatmayatfirstnotseemrelevant.Bear withme,allwillbecomecleareraswegoalong.

Preface
Awhileago,Ibecameinterestedinremappingcars,mainlybecauseIhadhadmineremapped,but hadbeenhavingtroublewithit,thinkinghowhardcanitbe?well,asitturnsout,quitedifficult! Themainprobleminremappingcarsisknowingenoughaboutwhatyouaredoing,really understandingandnotjustdecalibratingthings.Youcanneverhavetoomuchknowledgeaboutyour tuningtargetsspecs,betheyhardwareorsoftware. Withthisinmind,beawarethatremappingcarsisnotaskillyoujustacquireinashorttime.Ittakes alotoftimeandareallybigamountofdedicationtodoitright.Also,itwonteverbecheaper(in toto)thanaremapyoucanbuybutyoullhavegainedlotsofknowledgeintheprocess. Alwaysbeawarethatyoucaneasilykillyourengineifyoudontknowwhatyouredoingsoalways tryandfindoutasmuchasyoucanbeforeactuallytouchinganything!Besuretoconfirmyour resultsanddologrunsaswellasuseaboostgaugewithwarningfunction,especiallyonpowerful setups.Itcansaveyoualotoftroubleandmoney Anotherthingtonoteisthatclaimsofsuperiorgasmileageviatuningareprettymuchuselessonly thedriversrightfootdeterminesfuelusage,soratheradjustyourdrivingstylethangeteco tuning!AlthoughitispossibletotuneforeconomyalittlebitbyplayingwithSOI,youwillnever realizeasmuchmileagegainsaswithdrivinginamoreeconomicalway. Soletsgettothegoodstuff!

Chapter 1 Planning

Where do you want to go today?

First,figureoutyourplannedperformanceandwhathardwaremodsyouwillneedtoreachit(if any).Meaning,figureoutwhatkindofremapyouwanttodoaStage1withonlysoftware changes,aStage2withsmallhardwarechangesoraStage3withlargehardwarechangesfor extremeperformance.Forthis,youllneedtoknowyourstockhardwareslimits.Ithelpstolookat similarcarsortheavailableengineoptionsforyourmodelforbetterreference. ComparisonALH90hp/210Nmstock1.9lVP37TDI(notexact,justforcomparison) Stage1 Stage2 Stage3

120hp/270Nm Softwareonly

150hp/320+Nm

1802xxhp/350+Nm

pluslargerinjectors,upgradedclutch, plusupgradedturbo,intercooler, noEGR,decat,singlemassflywheel pumpplunger,exhaust,downpipe,6 gearconversion,extrafuelpump

It all depends on your goals and your budget. It doesnt pay to overtax your hardware rather be conservativeinyourpowerfiguresandhaveyourcarwork.

What can my stock hardware take?

Thisisabittoughertoanswer,butIlltrytoillustratebasedonmyowncar. Transmission The stock ALH is equipped with an 02J 5speed manual gearbox rated for 250Nm of constant torque. Its maximum stock torque is 210Nm, meaning the stock map is well under the transmissions rated performance. Above about 270Nm of torque, youll need an uprated clutch and a single mass flywheel. Now,peoplehavemanagedtobreakthistransmissionwithstockpowerothershavemanagedover 400Nm without killing it for quite a long time / lots of kilometers, even in drag use. Still, itll break eventuallyifyoukeepabusingit,sokeepaspareoneifyougonutsonpower Again, it all depends on your driving style and on the condition of your hardware. Be conservative with torque on 02J 5speed gearboxes especially below 2k RPM. For extreme power and torque, consider upgrading to a 6speed gearbox or having your 5speed box reinforced. A limited slip diff wouldalsohelpgetallthatpowerontheroad. The 6speed manual gearboxes and flywheels are rated for 350Nm of torque and can take a little bit more than that, as well, about 380Nm. Above this, youll have to look at uprated clutches and a singlemassflywheel.Youllneedgearbox,clutch,startermotor,flywheel,gearleveretc. Clutch/Flywheel

The stock clutch will not hold much more than 270280Nm of torque, depending on its condition it mayevenholdless.SamegoesforthestockDMF(dualmassflywheel)itstartstoblock(hittheend stop on its springs) at around 275280Nm, as well. Be careful with your DMF, even new ones can be ruinedveryquicklybyafewWOTaccelerationsoutsidetheirtorqueenvelopeandtheyrunapretty penny! Consider upgrading your clutch to a Sachs Race Engineering or a Spec clutch, for example, coupled with a single mass flywheel. This combination is good for a lot of torque, more than the gearbox can takebut hell, it does bite! No comparison to the soggy stock clutch oh, and start exercising your leftleg,youllneeditforachange. Caveat: on 5speed transmissions, a single mass flywheel is audible when idling sounds as if somethings wrong with your engine, clacks a bit or rather, sounds like an old Diesel didthose didnt have dual mass flywheels, either. Its not that bad on a 5speed box, but on 6speed boxes its verydefinedandloudbeawareofthis. Turbos TherearequiteafewoptionstochoosefromwhenupgradingyourturboonanALHforexample: VNT15/GT1749V (90hp VEP original) can do about 1.21.25 bar above ambient safely but limit it at highrpms! GT1749VA(130hpPDoriginal)about1.5bar GT1749VB(150hpPDoriginal)about1.7bar GT1752/56hybridabout1.82.1bar,depending GT20/GT22orhybridover2bar These are listed from weakest to strongest. The VNT15/GT17 will fit without any or with only very minor modifications due to clips vs. no clips. Basically, youll need to figure out whether your model has a turbo with weldedon exhaust manifold or whether it has a separate one and shop based on this. You can usually rotate the housing to make the openings point where you need them to if necessarybutneverdisassembletheshaft/wheels!Yourturbowillneedtoberebalancedifyoudo oritwillkillitselfinshortorderifyourunitanywayandputloadonit. The GT20/22 will only fit with some modifications (custom manifold/ducting) and will spool pretty late compared to the GT17s, but when they do spool will produce a lot more air mass at the same boost pressure and enable very high performance numbers. Anything larger will probably not spool onthe1.9lTDIengineinausablewindowatallevenwithlargeinjectionsystems. Cooling Morepowergeneratesmoreheatinmorethanoneplace.Forone,higherboostlevelsmeanhigher IAT(intakeairtemperature).Thisisduetothefactthatairgetshotterasitgetscompresseditdoes getcooledbyyourintercooler,buthotterairinmeanshotterairout. Ifyourunlongerperiodsofhighload,yourenginecoolantandoilwillalsobecomehotterandhotter withdisastrousconsequences.Samegoesforyourgearbox.

So take an uprated cooling system into account a better intercooler never hurts, though it will not generate performance by itself, it will give better efficiency at higher boost levels and ambient temperature levels (i.e. summer). It will also make sure that you do not have thermal failure when you hit it during summer mediocre intercoolers can let IAT rise to near 100C at WOThigher IAT meanshigherEGT,which meansyourturboisglowingredandthinkingaboutditchingawheelifyou keeponabusingit,yourpistonsarenthappyeither, >150hp, you should really think about using an oil cooler/heat exchanger with a thermostat on an ALHifyouplantousethepowerforextendedperiodsoftime. Engineinternals OnVAGcars,youcouldalsoexchangethestockpistonswithsomePDones(butyoullhavetoswitch to trapezoid conrods from a BLS or ATD, for example to be able to fit the PD pistons) and if you get the right pistons (from an ARL, but just the pistons ARL/ASZ conrods will not fit), you can also realize a compression reduction just via the pistons themselves while reinforcing your engine via better piston coating and cooling. Youll also have to use the newstyle oil cooling jets to fit these pistons,though! You can install uprated conrod bearing shells with better surface treatment use sputter bearings if youcan,justmakesuretheyfityourcrankshafttheASZ/ARLoneswillnotfit,justliketheconrods. You could also realize a compression reduction via a thicker cylinder head gasket, but this is not the best method. However, if youve already got it apart, you could exchange the head bolts for 12.9 qualityones(stockare10.9)ifyouplanonhighboostlevels(about1.8baroverambientandabove).

What nozzles and what plunger piston should I use?

Ingenerallargernumbersmeanmoreinjectionquantity,butmoreisnotalwaysbetter.AnALH (European)usesa10mmpumpplungerpistonand5holenozzleswith.184mholediameterto achieveamaximumof51mg/stroke(albeitatverylonginjectiontimes);eventhoughthestockmap neverinjectsnearlythatmuch,thepumpvoltagetablegoesupto51mg/stroke. Thereasonthiscombinationisusedbydefaultandnotlarger.205,.216or.232nozzlesalongwith the10mmplungerpistonisthatsmallnozzlescombinedwithlargeinjectionpressuremakeforvery goodatomization/evaporationoftheinjectedfuelquantity,whichleadstobettercombustion, emissionsandlesssmokebuttheywillalsostrainthepumpandtimingbeltmore,thoughthis shouldbenegligibleifyouadheretobeltchangeintervals. Letsexplainthisbycomparingtwodifferentnozzleson10mmpumpplunger,bothinjectingthe samenetamountoffuel(5and50mg/stroke,thepumpvoltagemapvaluesaretakenathighrpm). 1) .184stocknozzlesduetothesmalleropeningsatthenozzletip,pressurebuildsup better/morequickly.ThenozzlestartstoinjectearlierandneedslaterSOI,butittakeslonger todeliverhighIQ 2) .216upgradenozzlesincontrast,thelargernozzlesneedearlierSOI(furtherBTDC)because theybuildupfuelpressurealittlemoreslowly,butittakesalotshortertodeliverhighIQ

5mg/stroke 1) .184nozzleswillneedabout1.5Vpumpvoltagetodeliver5mg/str 2) .216nozzleswillneedabout1.71.8V 50mg/stroke 1) .184nozzleswillneedabout4.7V 2) .216nozzleswillneedabout4.2V ThisshouldservetodemonstratethatjustscalingthepumpvoltagemapwillNOTwork!Were changingahydraulicsystemhere,itsabitmorecomplexanddefinitelynotproportional. Basically,alargerplungerpistonandsmallernozzlesarethewaytogowithinreason.I.e.you shouldnotcombinea12mmplungerpistonwith.184originalnozzlesandexpecthuge power...instead,youllputhugestrainonyourtimingbeltandpumpwhilestillnotbeingableto injectalotoffuelinashorttimeduetothesmallnozzles. Also,beawarethattheplungerpistonlimitshowmuchfuelyoucaninjectthisisahardlimitand notchangeableotherthanbyswitchingtoalargerone.Lookatareaforacomparisonofwhatthey candoi.e.an11mmplungerpistonwillnotdeliver10%morefuelvolume,but21%. Popularnozzle/plungercombinations .205or.216nozzles,10mmplungerthelargestyoushouldgoona10mmplungerIMO.Though .232andabovedowork,theygetsmokierandsmokierduetobadatomization .216or.232,11mmplunger .232+ona12mmorlargerplungerforextremeperformance Performance Itstoughtoattachrealworldperformancenumberstothesecombinations,becauseeveryoneis comfortablewithadifferentlevelofsmokeandhardwareabuseandhasperformedadifferent amountofmodsinadifferentlevelofquality. Immorecomfortableattachingmaximumperformanceorratherinjectionquantitylimitstopump plungerpistonssincetheirdisplacementdeterminesthemaximumfuelflowthatcanhappeninan absoluteway.GoogleforVP37functionaldescriptionsandlookathowtheywork,youllseewhy. The10mmplungercanbeusedtoinjectabout57mg/strokemaximumwith.216oder.232nozzles withverylonginjectiontimes.TheALHstockmaponlygoesupto51mg/strokewhy?Simple answer:becauseofpumpinglosses.Thehigherinternalpressurewiththestockinjectors(remember, smalleropening,higherpressure?)meansthatasmallamountoffuelcannotbeinjectedbutis insteadforcedbackwardsintothedieselreturnlinetobeinjectedanotherstroke,about6mg/stroke atambient(fuel)temperature. Sowiththelargerinjectors,thepressurebuildupislessandsoarethepumpinglosses,nearingzero with.232s.

The11mmplungercanbeusedtoinjectabout21%morefuelthanthe10mmone21%morethan 57mg/strokeisabout69mg/stroke.A12mmplungerwillbeabletoinject~44%morethana10mm one,orabout82mg/stroke. Allthesearetheoreticalmaximumnumberswhichwillbelimited/reducedbyyournozzlechoiceand howhightheresultingpressurelevelsandinjectiontimesare.Itdoesnthelptobeabletoinjectfuel thatyoucantburnbecauseittakestoolongtoinjectit. Insidethoselimits,youcanuseprettymuchanynozzle/plungercombinationandfindyourown compromisebetweenpower,smokeandEGTlevels.

Chapter 2 a basic Stage 1 remap

Whatisusuallydoneforastage1remap? 1) Adjustsmokelimiter,torquelimiter,driverswish 2) AdjustrequestedboostandN75map 3) Adjustfurtherlimiters(SVBL,boostlimitermap) Howisthisachieved? Iwontgointothebasicsofidentifyingandworkingwithmapshere,therearevariousverygood guidesonecuconnectionstohelpyou,noneedtoreinventthewheel. Basically,thereare3mainlimiterstodetermineIQ(injectionquantity): 1) Smokelimiteraxesareairmassinmg/strokeandrpm,valuesareIQinmg/str. 2) Torquelimiteraxesarerpmandambientairpressureinmbar,valuesareIQinmg/str. 3) Driverswishaxesarepedalpositioninpercentandrpm,valuesareIQinmg/str. Thelowestofthesevaluesatanypointisused. Youshouldshapeyourmapssothatthedriverswishisthehighestofthethreethenthesmoke limiter,andthetorquelimitershouldfitinsidetheareaenabledbythesmokelimiter(bethesmallest ofthethreelimitervalues). Inthemapeditorofyourchoice,identifyandmodifythesmokelimiter,torquelimiteranddrivers wishmaptoincreaseyourfuellinglevels.Youmayhavetomodifythemapaxesslightlytobeableto usefullIQforthesmokelimiter.Becarefulwithshapingyourtorquelimiterdontincreasetorque toomuchbelow2000rpm,betterhaveyourtorquemaxat2500/mintosaveyourgearbox,DMFand clutch. Calculatehowmuchtorqueyouwillneedforabout275NmonanALHorother5gearmanualcar withDMF/stockclutchanddontgoabovethisvalue.Thestockcarhas210Nm@1900,soyoushould beabletofigureoutanumber.Also,dontgomuchabove120hp(again,youcancalculatefromthe 90hp@3750thestockfilehashorsepowerisjustafunctionoftorqueandrpm!)oryourturbowill dieduetohighEGTsbecauseyourinjectiontimeswillbetoolong.

Now,youllneedsomemoreboosttobeabletoburntheincreasedfuellevelsorrather,youdont needmoreboost,youneedmoreairmassbutthatgetscreatedbyboost(andimprovedby cooling).Thestockrequestedboostmapgoesupto1950mBarabsolutepressureor0.95barabove ambient. Thestockturbowillnotdomuchmorethan1.21.25barforlongerperiodsoftimesafely.However, thisisenoughforastage1remap. Sowhereyouincreasedfuelling,alsoincreaseyourboostpressureinasensibleway,meaningdont requestwaymorethantheturbocancreateinyourmap,thatwillleadtospikes.Beespecially carefullowdown(<2krpm)topreventsurging(uncontrollableheavyoverboost). Analogoustothis,takecaretoopentheVNTvanesabitmorewhereyouinjectmorefueland adjusttheN75mapaxisifyougoaboveit,extrapolate. Youcanalsocheatandlookatothercarswithhigherpoweroutputfromthesamerange.The requestedboostvaluesandN75mapfromthe115hpPDmodelmightbeagoodstart,forexample. Now,withoutadjustingsomemorelimiters,wewillnotbeabletousetheseboostvalues.Namely, therearetwotheSVBL(singlevalueboostlimiter)andtheboostlimitermap. TheSVBLisasthenamesuggestsassinglevalue.OntheALHstockfile,ithasthevalue1990 andstandsfor0.99baraboveambient.Thisis40mbarabovethehighestvalueintherequested boostmap.TheECUusesthisasasortoftuningprotectoryourrequestedboostvaluesabovethe SVBLwillnotwork. Theboostlimitermapitselfisusedasalastresortifactualboostisabovethisvaluefortoolong, limpmodeshouldbeengagedasasafeguard.Thestockboostlimitermapis2150mBar(1.15bar aboveambient)upto4500rpmandthengoesdownto0.8barat5012rpm.Thisis200mBarabove maxstockrequestedboost. Takecaretoadjustthesesensibly. ..tobecontinued. Stilltocome: Stage2and3remapconsistingof: Creatingacustompumpvoltagemap Extendingdiagnostics Extendingboost/IQ/airmasslimiters CalculatingandadjustingSOI Changingsensorlinearization MAPandMAFbasedsmokelimiting

Changingidlespeed Dynamicidle