Calibrating 100% nozzles on 1.9TDI PD AVF EDC15p+

[Cotulla]

Hi, I fitted 100% Jetex nozzles to my injectors. How to calculate durations? I‘ve been told to cut duration by about 30% and Adjust SOI to end up at the same EOI. Wich I did but the engine would start up rough and still give me lots of smoke above 2000rpm. It also would idle very badly. Thinking about it, this can‘t be as simple as just cutting duration by x% because on the PD engine the injection pressure depends on the rpms. Is there a way, a guide to adjust duration and SOI? It just has a little tune on it the rest of the car is still stock, I want to get it as close as possible to be running identically to before the swap. And changing other variables(Turbo) In the system afterwards. Maybe somebody has a good file for 50% or 80% nozzles, this sure would be of help.

[chrisimerk]

i got tunes for 80% nozzles i have no clue why you want 100% as i wouldn't go more then 80% with standard head bolts and gasket as it will start to lift the head then you will have problems lol post file here i can make it run correctly what other mods do you have?

[Cotulla]

I wanted to go 100% just to be save in the future and not have to worry about the nozzles if I decide to go with an even bigger Turbo. I also have a 4 bar MAP sensor, 12.9 Headbolts (ARL) and ARL conrods. I want to fit a GTB2060VKLR or even a GTB2260vklr in the future. The file below is just a simple tune where I extended durations to 70mg and boost to a little over 1.5 bar. Worked great for years now.

[chrisimerk]

I wanted to go 100% just to be save in the future and not have to worry about the nozzles if I decide to go with an even bigger Turbo. I also have a 4 bar MAP sensor, 12.9 Headbolts (ARL) and ARL conrods. I want to fit a GTB2060VKLR or even a GTB2260vklr in the future. The file below is just a simple tune where I extended durations to 70mg and boost to a little over 1.5 bar. Worked great for years now.

here try this i have taken the maf off so it will be running from map to take full advantage of the 4bar map.

also 80% calibration this was running good on another car i tuned.
i have only modified duration soi and yaxis

test and report

pass in pm

[Cotulla]

I've looked into your map, the only thing concerning me is that you changed N75 map, couldn't this lead to overboosting and damaging the turbo? Or is that change for better responsiveness?

[chrisimerk]

It's for responsiveness it will not over boost with those different values this is a tested n75 setting never over boosted and it irons out boost surge also. Everything I have changed whithin your file is tested changes no problems
Write it you will see.

Regards

Regards

[jurebv]

i got tunes for 80% nozzles i have no clue why you want 100% as i wouldn't go more then 80% with standard head bolts and gasket as it will start to lift the head then you will have problems lol post file here i can make it run correctly what other mods do you have?

why would 100% injectors lift head? :D you could have 10000% bigger injectors and inject oem stock mg amount...

[chrisimerk]

why would 100% injectors lift head? :D you could have 10000% bigger injectors and inject oem stock mg amount...

He doesn't want to Inject oem mg amount now does he mate he is trying to push big power thus increasing soi which is the main cause of head lifting and blowing head gaskets.

why would you want to fit 100% injectors if your going to keep it at oem mg?

I said it would lift head with 100% injectors being the mods he has fitted or will fit as increasing duration and soi could cause this without using either pd150 head studs or Apr also you can see from the files he has been making he has been messing with duration and soi.

I know using 100% injectors won't lift head but using 100% injectors you then have the means to do so.

Also I said 80% injectors are good enough to push big power around 350bhp and don't really need 100% injectors
Unless you got deep pockets lol

Regards

[Cotulla]

As I mentioned above, I've fitted the stronger 12.9 hardness headbolts from the ARL engine. Is that gonna be enough or might the head still lift? I will try the file tomorrow.

[chrisimerk]

As I mentioned above, I've fitted the stronger 12.9 hardness headbolts from the ARL engine. Is that gonna be enough or might the head still lift? I will try the file tomorrow.

Hi mate that was not to you it was to the other chap.

Depends how much power you want to push the pd150 head bolts are capable of around 300bhp anything more then that I would either go Apr or a better head gasket as even if you do the headbolts you then have the gasket which is the other weak point.

But yes the pd150 head bolts are fine if you don't go silly with duration and soi.

some advice on your build change the cam even port the head will free up a load of power capabilities as the stock cam your basically hitting a brick wall at 260bhp and can't get anymore.
Get a egt sensor fitted as you want to keep and eye on that.

Regards

[Cotulla]

EGT sensor after Turbo is already installed. It also has a 272° camshaft, I'm looking for around 280 hp but with nice smooth tourque as not to kill the new flywheel.

[chrisimerk]

EGT sensor after Turbo is already installed. It also has a 272° camshaft, I'm looking for around 280 hp but with nice smooth tourque as not to kill the new flywheel.

Good stuff mate I can assist you in chasing 280+ got a few tested tunes being my own vrs I use to own made 364bhp tuned by me on dyno that was with meth also.

Regards

[Cotulla]

Today I finally got to testing the file. Smoke while ideling and cruising is gone. Full throttle: 1600-3000rpm visible smoke and 3000-4000 very much smoke (still less than with stock durations).

at 1800-1900rpm I get shaking from the engine, just a little bit (it still pulls like before, so no real torque increase). Flywheel is 1 year old and engine/gearbox mounts are new. Maybe to early or to late EOI? (I couldn't log it as I was alone today, I try to get a log as soon as possible)

[chrisimerk]

yeah get logs and ill try sort out the shaking between those rpms

regards

[Cotulla]

Hi, we did some testruns and it seams to me that boost is rising to quickly at those rpm and the ecu corrects in that case ("slight stutter" from the engine as it tries to protect itself, aka fuel cutoff, but it happens too fast for VCDS to catch it). Or do you maybe spot another problem in the logs attached below?

[chrisimerk]

Yeah I have not messed with boost or limiters I have only changed maf to map 80% lin and n75 put n75 back to standard with winols see if your problem persists.

Regards

[chrisimerk]

Hi, we did some testruns and it seams to me that boost is rising to quickly at those rpm and the ecu corrects in that case ("slight stutter" from the engine as it tries to protect itself, aka fuel cutoff, but it happens too fast for VCDS to catch it). Or do you maybe spot another problem in the logs attached below?

here mate try this i have modified n75 and you missed some boost maps and limiters

pass in pm

[Cotulla]

Hi which maps did I miss? What do you mean by 80% Map lin?

[chrisimerk]

Hi which maps did I miss? What do you mean by 80% Map lin?

Boost request map and boost limit map in the next code block where missed and sorry it's short for linearization