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Thread: Karls OE PLUS TDI Wagon

  1. #1
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    Karls OE PLUS TDI Wagon

    This is a potted history of the car and most of the mods on it. Being an Admin on UK Passats I spend a lot of time on there so I have copied my build thread off there.
    Sorry for the links to the various UK Passats how to's I have done, I know some forums are a bit touchy about that if you want me to remove them I will. But they do contain useful information.


    Bought the car in Feb 2006 a 2002 130 BHP 1.9 TDI SE with 79K miles on the clock with one previous owner. Had looked at about half a dozen cars before and some were real sheds. This was a nice honest car with a full VWSH and some nice optional extras , cruise control, sunroof , fog lights and a 6 disc CD changer.
    Heres a picture.



    This was my first VW having owned many Vauxhalls over the years, Vivas, Astras, Cavaliers , Vectras etc. I have always done my own maintenance and had only ever taken a car once to a garage for work in 25 years , I had an issue with the airbag on my Vectra, having no diagnostic tools I was forced to goto the garage .
    When looking for a replacement I looked into car diagnostics and found VAG-COM. Thus the search was on for an A4, Octavia or Passat. The A4's were too pricey, the Octavias not cheap enough compared to the Passats, so a Passat it was.
    I first came across the forum when looking for information on why the car might be smelling musty, I originally put it down to the fact that the car had been standing for a while. After a few weeks of air freshners and no obvious issues I found the pollen filter seal was the culprit.
    Carpet dried out, pollen filter seal replaced the car was a much nicer place to be, fortunatly I never suffered any other major issues.
    Also the car had an issue with the temperature gauge bouncing up and down, again from this site I found the CTS was intermittent and changed it.
    Decided to get some different wheels as the wellingtons were a bit tatty and spotted some B6 Catalunya wheels on Ebay almost new for just over £100, it of a bargain.



    Car still not lowered and this was bugging me as the standard car is pretty softly sprung and rolls around like a barge compared to most of the Vauxhalls I had which were a lot more stiffly sprung.
    Found a cheap spring and damper kit on Ebay 40mm lower about £180 all in and put that on.







    The uprated shockers are still on my car today and working well. The 40mm springs were a little soft when the car was loaded with kids, a boot full of stuff and a Caravan on the back so switched to some Eibach 30mm springs which I got off Fleabay second hand for a really good price.
    The Eibach 30mm drop rear spring was shorter than the 40mm drop rear spring as it's spring rating is higher the car handling wasn't quite as good but it got over speed bumps when loaded.

    Fitted some HID lights on the dipped beam with a cheap £30 kit off E-bay and they make a vast difference
    before


    and after



    The camera was set to manual so the exposure time and aperture were the same, so you get a good idea of the improvement, these were 6000K bulbs.


  2. 207Bhp 345Lb/ft 14.95 seconds 93mph http://www.staffs-vw.co.uk/staffs-vw...tdi-wagon.html

  3. #2
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    Re: Karls OE PLUS TDI Wagon

    The idea was always to keep the car looking pretty standard but to improve it in certain areas such as handling, brakeing and performance and adding some more comforts.
    Bought a cheap reversing sensor kit off E-bay and fitted this along with a new rear lower spoiler which was only about £35.





    Also decided to change the wheels for some Audi A4 sport items as the Catalunyas had been through 1 winter and corrosion was already starting to show under the lacquer even though the wheels hadn't been kerbed or anything.
    Again Ebay came to the rescue with a nearly new set of rims off an A4 sport where the owner fitted 18 inch rims and I bought the 16's for just over £100 with the postage. I like these wheel rims easy to clean, and they are cheap to buy extra ones, I have 6 in all with the winter tyres on.



    You can see the rear Lexus look chrome lights that I had on the car for a year, bought them because I thought they would make the car look better, they were Ok on a silver car but they were FK items and the quality wasn't that great and they kept getting misted up so put the standard lights back on.

    I changed the glow plugs on the car and did a how to for that to help other people out after I had seen so many people take the car to a garage to do what is essentially quite a simple job.

    UKpassats.co.uk • Login

    I started to up the power of the car with an Alpin digital tuning box that I bought off EBAY second hand, ( there's a theme appearing here) this gave the car a good power increase and didn't really affect the fuel economy win/win I would later find out this was increasing the power to around 155bhp and 260Lb /Ft of torque.Not bad for a £50 plug in box, remaps were not as cheap then as they are now.
    The power increase was adjustable by moving the jumper, strangely it's set in the most powerful position . Advantage of this system is if you turned the power off to the box the car reverted to normal, handy in the winter when you really didn't want all the extra torque.



    With the power increase and now as I had 16 inch wheels I could uprate the brakes which needed new discs on anyway. Sourced some new caliper carriers and a set of Mintex Red Box discs and pads and the brakes were markedly improved overnight a very good mod.



    There's not a lot of clearance with the caliper, They are the biggest brakes you can get with 16 inch wheels.



  4. 207Bhp 345Lb/ft 14.95 seconds 93mph http://www.staffs-vw.co.uk/staffs-vw...tdi-wagon.html

  5. #3
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    Re: Karls OE PLUS TDI Wagon

    Moving on with improving the performance of the car decided to decat it.
    Thought I would be smart and bought a secondhand cat off fleabay to mod and then keep the original one just in case.



    Instead of just smashing the core out I decided to drill a hole clean through the monolith. Why , because I could.
    Also I had read that the large empty can thats left can cause resonance and vibration issues at certain RPM's so figured just putting a hole through the middle would leave most of the monolith in.



    Had an isue when I came to fit it though as the cat on my car was in one piece with the downpipe. You can't really see the bolts on the flange that join the two parts whe looking from the engine bay so didn't realise mine was a one piece item. So had to buy a downpipe to fit my new cat.
    If you have a one piece cat on your car you would have to chop the pipe off to knock out the monolith.



    Fitted it and it improved the spool of the turbo a bit and also produced a bit more turbo twitter and whistle from the exhaust.
    I later decided to go the whole hog and knock the monolith out while I had the exhaust off the car when I was upgrading the turbo. It didn't make any more noise or make any difference so should have done this in the first place.

    The price of remaps was coming down and after much investigation decided to go for a Custom Code Phase 1 map so took the car to Midland VW to get it remapped.
    Handy for me as it's about 2 miles down the road. Great bunch of guys who do a great job and don't charge the earth.

    Midland VW



    After some tweaking ended up with this



    The standard car was measuring 128bhp, a little low as most come out more than 130 and more like 135bhp. They put it down to the transmission losses which were very low, thus the calculated crank power figure is low .
    There are 3 runs on the graph,
    The tuning box turned off 128 bhp 213 Lb/ft
    The tuning box on 153 bhp 261Lb/ft
    And the remap 165 bhp 271 Lb/ft

    The car was completly different to drive so smooth it was like a petrol car the way it revved to and past the red line, this can be seen in the graph, when I could keep away from the accelerator the car would do a few more MPG, it was also quieter and the idle smoother.

    207Bhp 345Lb/ft 14.95 seconds 93mph http://www.staffs-vw.co.uk/staffs-vw...tdi-wagon.html

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    Re: Karls OE PLUS TDI Wagon

    Continued adding bits to make the car nicer to drive. Replaced the CD changer with a connects2 MP3 player. This connects to the head unit and you store the MP3 tracks on an SD card. 6 folders each with 100 tracks in so effectively you have a 600 track jukebox. Not as good as a Phatbox syatem but it was less than £30 off Fleabay.
    I have done all the amps and sub bit with other cars and wanted to keep it simple.





    Found a post that explained how to get the windows to work off the remote, you could use a VAG-COM lead to do this so wasn't going to cost anything to do. Downloaded the program and after about an hour fiddling around I had the windows working with the remote.This only works with a serial VAG-COM lead not a USB one. Theres a how to here.

    UKpassats.co.uk • Login

    And a You tube video to demonstrate what it does. This guy did his windows the same way I did.



    A while after I had done my windows a company produced a program that will run on a laptop with a USB VAG-COM lead to automate the wimdows. It is much easier to use but has a downside as it only works with one CCM type, however that CCM is the one used on nearly all B5.5 Passats.
    The program is called Motordiag and there is a very good how too here

    Auto close/open windows tutorial. - Skoda Octavia I - BRISKODA.net - The Skoda Forum and Community


    Noticed that the wheelarch clearances weren't the same at the back or the front and after looking around all the suspension discovered one of the rear bushes was shot.
    Replaced these and did a bit of a how to as well.

    UKpassats.co.uk • Login




    Whilst still looking to improve the performance I noticed people talking about a plug and play turbo upgrade using a BV43 which is a turbo off the Audi A4, A6 170 TDI car produced around 2005-2007.
    These were supposed to be good for about 220bhp with the right mods and tuning.After much searching on Ebay (where else) spotted one that needing rebuilding and was a 99p start auction. Dropped the seller a line asking what was wrong with the turbo and he said the car it came off was smoking. I bid on the turbo and got it for less than £30 with the postage. Great I thought until it arrived, the turbine wheel had snapped off the shaft and basically the turbo was scrap. The guy did say it needed a rebuild and I bet the car was smoking. Ebay is not always a great place .

    Continued to look and spotted one a few weeks later being sold off a car that was being broken. It looked good and the seller had great feedback. It was £250 delivered so I bought it. However when it arrived it was damaged, the plastic connection on the vacuum actuator had been broken off in the post, it wasn't good, you could see that it was there on the photo on Ebay.



    I spoke to the seller and said I could source a second hand actuator but it was going to cost £50, he credited me £50 back and I used the actuator off the scrap £30 turbo I had bought so was £20 up on that deal .

    There doesn't look to be much difference between the standard turbo and the BV43







    The BV43 will support 1.8 bar boost though which is nearly 27 Psi boost.

    There is a lot more info and pictures in a how to here

    UKpassats.co.uk • Login

    Also a how to on how to remove the turbo to enable the vanes to be cleaned

    UKpassats.co.uk • Login


    As part of the change over from the standard turbo to the BV43 I replaced the standard Side Mount Intercooler ( SMIC ) with a Front Mount Intercooler ( FMIC ) . The extra boost when the car is mapped means that intake temperatures are much higher and the standard SMIC cannot cope with these on a 200BHP engine.
    Over to Ebay again and ordered a universal kit and fitted this at the same time as the BV43 .
    In line with keeping it all low key I sprayed the intercooler and all the pipework matt black, you can't see the intercooler from the front. It does a great job of keeping down temps especially in the summer when the SMIC would have heat soaked and you would have definately seen a drop off in performance.



    I appended all the photo's and information to another very good How to already existing for a FMIC install done by Mini Dub.

    UKpassats.co.uk • Login

    Returned to trying to make the car handle a bit better after seeing threads on other forums and looking around bought a top suspension cross brace off DMCessential off a W8 that he had broken and bought the two end brackets from the local Audi dealer.



    Also when looking at ETKA ( The parts database for VAG cars) one day Looking for some part numbers for someone on the forum noticed a part on the suspension diagram that didn't have a mention in the parts listing. This usually means it's used on another model such ans an A4 or A6 as the diagrams are generic a lot of the time. After some searching discovered it was a suspension cross brace that closed off the back of the subframe to turn the U shape into an 0. Enquired at the local Audi dealer as VW didn't stock the part and it was around £14 so bought and fitted it.



    The combined effect was to tighten the front end improving turn in no end. These parts are fitted to cars such as the RS4, RS6. Theres a how to with details and more pictures here

    UKpassats.co.uk • Login

    Also whilst looking at ETKA noticed that some of the bigger engined cars had a flap on the back of the radiator grill to direct high pressure air to the intake, thus improving performance at higher speeds. I had already drilled holes in the top of the grill where the intake sat behind as again I had noticed on some cars the holes were open on others they weren't there.
    A small cheap mod, the flap is only £2.66 and clips to the back of the standard grill.





    Theres a how to here with more pictures and details

    UKpassats.co.uk • Login

    Decided to revisit the exhaust after seeing this video on you tube



    I already new the rear box was a bit of a restriction and many people just replace the complete exhaust back to front with a pipe. I didn't want to go that far as the noise of a completly unsilenced car is a bit excessive, not as bad as some peoples petrol cars but not for me. Didn't fit in with the daily runner OE look.
    So replaced the rear box with a 2.25 inch chery bomb that was made by John Ashley exhausts in Walsall. They know what they are doing and I would recommend them to anybody who wants a custom exhaust.



    Theres some videos and more information in a how to here,

    UKpassats.co.uk • Login

    This improved the low speed pick up quite a bit as the BV43 struggles at lower RPM compared with the standard VNT17 turbo.

    207Bhp 345Lb/ft 14.95 seconds 93mph http://www.staffs-vw.co.uk/staffs-vw...tdi-wagon.html

  7. #5
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    Re: Karls OE PLUS TDI Wagon

    Decided to upgrade the brakes a bit and change the compound as I spotted some Yellowstuff pads on Ebay for £35 should be twice that price and they do work very well excellent cold grip just the same as OE but when they get warm or hot they are brilliant. A bit dusty but most of the time my car isn't the cleanest and the dust does come off fairly easily without damaging the wheels.



    I have since put greenstuff pads on the back as I had to replace them, this hopefully balances the braking back up, I have never had an issue but plan to take the car to the odd track day so really need the brakes sorted.


    Before doing any more power upgrades I decided to upgrade the cylinder head bolts. It's a worth while mod to change the head bolts to those used in the 150BHP ARL engine. These are uprated High tensile bolts and will hopefully help to stop "Head lift" which could lead to a blown head gasket.
    They were around £35 from Ebay but places like Darkside Developments stock them as well. Just remove the existing headbolts one at a time making sure no or very little oil runs down the holes when you remove the old bolt.
    I started in the centre and worked outwards in a spiral pattern undoing one at a time and replacing it.


    After running around for a year with the BV43 on I eventually got around to getting it remapped to a stage 2 to get the most out of the setup. The brief to Chris at Midland VW and Custom Code was to egt the most out of the setup without producing loads of smoke and without generating massive amount of torque as the car is still running a standard 228mm LUK clutch and DMF, All be it I had the Clutch and DMF changed at 117K miles because it was slipping occasionally when towing the caravan.

    I dropped it off a Midland VW on a Friday morning and rode back home on a bike I put in the boot, handy living just down the road. Rang them up at lunch for a progress update and they were still working on the car. Rang up in the afternoon and they were having some problems getting the map to make decent numbers. I rode back down and saw Chris at work, Took the car out for a test drive and it was quicker but not that much compared to before, but this wasn't the final map.
    Had to take the car back Satuurday morning when they loaded the final map on and put it on the rollers.



    There are 3 lines on the map, all the runs are with the same hardware setup on the car bv43, FMIC etc but different programs in the ECU.
    With a program simulating the stock ECU the car made 139 Bhp and 217 Lb / Ft of torque
    With the phase 1 map on it was making 174 Bhp and 260Lb / Ft of torque but you can see the power was going all the way past the red line I had made up and fitted a buzzer that went off when the revs got to 4800 as it was quite easy in second and third to find the car going a bit flat as you had hit the rev limiter around 5100 Rpm.
    With the new phase 2 map the car was making a nice 196bhp and 323 Lb/ft of torque.
    I was hoping for more than the magic 200 Bhp but the car doesn't hardly smoke at all and the torque is not excessive, indeed the clutch coped fine on the dyno.

    207Bhp 345Lb/ft 14.95 seconds 93mph http://www.staffs-vw.co.uk/staffs-vw...tdi-wagon.html

  8. #6
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    Re: Karls OE PLUS TDI Wagon

    I decided to improve the look of the car by putting some spacers on the wheels to move them out. This does 2 things improving the look of the car but by widening the track it aids stability slightly and improves the handling.
    By moving the wheel out of the wheel well it reduces the gap between the top of the arch and the tyre making the car look lower than it really is.
    Before it looked like this



    With 15mm spacers front and rear it looks a lot better



    When the car was having it's MOT and it was being moved around I noticed the front of the engine seemed to be going up and down quite a bit. Looking into this I found that there is a rubber buffer fitted to the front of the engine that controls the amount the engine rises when you accelerate.
    Due to the layout of the engine and transaxle when you accelerate there is an equal and opposite force created that tries to lift the engine up at the front.
    The Snub nose mount tries to counter this. on the lower powered cars this is made of a foam rubber type material on more powerful models it's a harder rubber.
    Heres a new original part on the left and the replacement uprated part on the right.



    The old one was well battered



    This is the housing it fits into on the front of the engine, the old one was well squashed at the top.



    More details in a how to here

    UKpassats.co.uk • Login


    Decided to add some instruments to the car, I had toyed with the idea of making a digital display using a 40 characther alphanumeric display and an Arduino controller wihich I bought and started to play with but just haven't got the time these days or patience to play with this. So looking around at traditional instruments found the Newsouth performance gauges.
    These are made in America hence the EGT being in Farenheit. The boost gauge is designed for performance diesels not having vacuum part as you never get a vacuum on a diesel and going upto 35 PSI leaves room for improvements. Boost spikes to 30 PSI and settles back to around 27 Psi when giving it some beans on my car.
    Unfortunately my Ebay skills deserted me and I had to buy these new from Awesome GTI but the pod was at least cheaper off a forum member.
    Whilst I was at it fixing the pod I decided to upgrade from the old 4 spoke SE wheel to a 3 spoke sports item. Again E-bay came to the rescue with a mint 3 spoke wheel off an Octavia VRS, nicer I think than the plain wheel on the Passat sport and an airbag all in for £60.
    You can see the new wheel and gauges





    I added more photos and information to a how to here

    UKpassats.co.uk • Login

    Decided to improve the illumination in the car with an LED bulb kit.
    This was around £22 all in off Ebay and replaced every bulb in the car with an LED.



    The inside of the car at night is now very bright when you open it .

    Looking for other ways to tweak the performance and improve things I decided the viscous fan had to go, although not a great consumer of power it also cooled the car unnecesarily a lot of the time so it had to go.
    Had a look around the scrap yards and found this fan in a Hyundai I think, can't remember which model but it fitted nicely and I wired it up with a relay to the fan temperature switch located on the bottom of the radiator pipe.
    Had to cut the existing viscous fan up to get the hub off it to mount the pulley for the belt so there was no going back. I haven't ever heard the fan come on, I find that in the summer I have the climate on which uses the existing electric fan so the engine just never gets hot enough to switch on this fan.







    And again looking to improve the power I bought a 2.5 inch THS decat downpipe, a very nice piece of engineering that will with the addition of a straight through Milltek box I bought of Vwnutant hopefully result in a few more ponies. I am holding off fitting the box and getting rid of the centre box resonator until I have improved the clutch as I do find it slips every now and then in fifth gear.
    I don't really need any more torque at the moment.







    For reference here are 2 videos I shot to get a handle on how loud the car was without the middle box.
    The first is the downpipe only, no cat on this or any other silencers and it wasn't deafening. I have heard louder petrol cars with sports exhausts on.Just click on the picture



    putting the silencer on the end of the downpipe quietened things down a load and I think this won't be much if any louder than stock.


    207Bhp 345Lb/ft 14.95 seconds 93mph http://www.staffs-vw.co.uk/staffs-vw...tdi-wagon.html

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    Re: Karls OE PLUS TDI Wagon

    Decided to take the car to Santa pod for a day out at the GTI Festival event never been there before and it was one of those things that I hadn't ticked off.
    Had a great time and suprised a few people including myself. I knew the car was quick when it got moving but to be running similar times to R32 golfs and beating cars that should be a lot quicker than my 1.9D family estate was quite good.
    Heres a MK3 golf 2.8 VR6 172bhp, a lot lighter than the Passat as well. This was only my 5th run up the strip and I hadn't got the traction control off and worked out the best way to try and get the car moving.



    This video was shot by somebody on the Briskoda forum of me running against the Golf and I found it on Photobucket.



    Heres a copy of my timeslip



    Fastest I managed was a 15.27 at 92 Mph

    And some more shots that were taken by the photographer at the track.





    Theres more info and stuff here

    UKpassats.co.uk • View topic - Gti Fest Santa Pod anyone going????

    That got me thinking about the issues I was having with the car regarding clutch slippage as the standard 228mm LUK clutch and DMF were doing a great job, I didn't get any clutch slippage at Santa Pod as I never hit 5th gear.
    Possibly I could kill 2 birds with one stone and sort the clutch and improve the performance again by replacing the 5 speed box with a 6 speed one.
    The problem with the 5 speed box in drag racing is that in 4th you can geto around 112mph but in a 1/4 mile race I was only hitting 92mph which was only about 3900 rpm, not even maximum power and pulling a higher gear as well for quite a period of time. The 6 speed box 4th gear only runs to around 96mph so will keep the car right up there in the power band plus it's pulling a lower gear so will accelerate faster.
    And a member of the forum was breaking his car as unfortunately the cam belt idler decided to detach itself wrecking the engine.
    I bought the gearbox, starter motor and DMF, Clutch and pressure plate and a new 6 speed gear selector knob and boot.Its an earlier ELN box made by Getrag and had a recent oil change .





    The clutch is a sprung one even though it's on a DMF and is the same one used on the V6 engines as is the pressure plate so hopefully it will handle the power a bit better. It's done less than 100 miles as it had just been recently fitted, you can still read all the part numbers on the friction surface of the plate.
    You can see on the side of the gearbox a plate that I have made, unfortunatly the 5 and 6 speed boxes have different mounting points and as such different subframes. Instead of replacing the subframe I plan to make an engine mounting to use the existing 5 speed mounting spot.Unless somebody knows of an engine mount that will do the job. I have been backward and forward through ETKA and the net and cannot find anything.
    I just now need the 6 speed change mechanism to complete the swap.

    207Bhp 345Lb/ft 14.95 seconds 93mph http://www.staffs-vw.co.uk/staffs-vw...tdi-wagon.html

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    Re: Karls OE PLUS TDI Wagon

    I have recently changed the front ARB to that from a sport, the handling was pretty decent but always let down by the amount of roll in the car. After looking on ETKA and doing some investigation it appears that the sport gets a solid 29mm anti roll bar and any estate of a lower spec gets a 29mm hollow roll bar.
    I spent £20 and bought a roll bar off a forum member who was breaking a 2.5 V6 sport which has the 29mm solid bar on and fitted this , wow what a difference probably the best £20 spent in terms of handling improvement. If you don't have a sport fit a 29mm front solid ARB.
    They seem to have green paint blobs at both ends and the middle, where as the hollow bars have a yellow paint blow in the middle and are considerably lighter. Something like 4Kg verses 7Kg.



    Heres what the hollow one looked like when I chopped it



    I have gone on a diet to lose the extra 3Kg I have added to the car .

    Theres more info here in this how to.

    UKpassats.co.uk • Login

    207Bhp 345Lb/ft 14.95 seconds 93mph http://www.staffs-vw.co.uk/staffs-vw...tdi-wagon.html

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    Re: Karls OE PLUS TDI Wagon

    Last part of my 6 speed gearbox Upgrade arrived today, A complete 6 speed gear change mechanism £40 delivered from where else Ebay. Fortunately the joint on the gear selector mechanism has very little play in it and the boot is intact so won't bother rebuilding it.



    Need to get some new flywheel bolts and one or two other bits, just need a week of glorious sunshine as well .

    Karl.

    207Bhp 345Lb/ft 14.95 seconds 93mph http://www.staffs-vw.co.uk/staffs-vw...tdi-wagon.html

  12. #10

    Re: Karls OE PLUS TDI Wagon

    A real build thread... but you have to be a member to read the threads on uk passats though...

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