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Old 11-09-2015, 09:20 PM   #1
loganp
 
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My first TDI

Just bought a 1999.5 Jetta TDI 5 speed with 230k miles. Gonna start with an intake, exhaust, and a set of gauges, need suggestions for a good tuner I can switch between economy and power. Thanks

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2004 Dodge QCLB, '97 12 valve Cummins swap, NV5600, 4x4
BHAF, 4" exhaust, pump mods, Southbend 3600

1999.5 VW Jetta TDI, 5 speed
Panzer skid plate, Profi Diesel 2.5" exhaust

1994 Dodge SCLB, 12 valve Cummins, auto, 4x4
BHAF, 3" straight pipe, pump mods
 
Old 11-09-2015, 11:19 PM   #2
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Get the intake cleanedand get rid of the EGR stuff immediately so all these so it does not take back up in there again.

No need to have a switchable tunes for these cars in my opinion. My Malone stage 4 tune with all my mods still gets great mileage and makes 60 more horsepower than it started with.

Do you know the history on the timing belt?
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Old 11-10-2015, 10:48 AM   #3
loganp
 
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Ok. How far can these be pushed with the stock clutch? And yes, previous owner who is a helicopter mechanic thought he should be qualified to change a glow plug but it twisted off in the head so the head came off and was totally rebuilt, new pulleys, new water pump, new belt tensioner, and new timing belt was 30k miles ago. He had a pretty good stack of receipts with it. These ALH engines don't break cams like other models right?
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2004 Dodge QCLB, '97 12 valve Cummins swap, NV5600, 4x4
BHAF, 4" exhaust, pump mods, Southbend 3600

1999.5 VW Jetta TDI, 5 speed
Panzer skid plate, Profi Diesel 2.5" exhaust

1994 Dodge SCLB, 12 valve Cummins, auto, 4x4
BHAF, 3" straight pipe, pump mods
 
Old 11-10-2015, 11:22 AM   #4
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This seemed like a good thread.
http://www.competitiondiesel.com/for...d.php?t=185409
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Old 11-10-2015, 03:45 PM   #5
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Welcome to the chaos

Malone has a switchable tune but will only work with a 2000+ car. The 99.5s are a little different.

ISSPRO for the gauges, AFE for the intake and straight pipe it. I would recommend Malone for it.
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Bagged 00 Jetta big turbo TDI - DRTY DZL
Bagged 03 Jetta Wagon TDI - DALY DZL

07 Dodge Ram Dually 12v swapped g56 - HULN DZL

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Old 11-10-2015, 07:14 PM   #6
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Woohoo! Looks good! Mines white too, I like the black trim.
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2006 Dodge 2500 Megacab, 2" level w/35" tires, AFE intake, 5" TBE, 50hp BMS sticks, FASS 150, EfiLive

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Old 11-10-2015, 07:59 PM   #7
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Quote:
Originally Posted by RDPsmoker View Post
Like I said in this thread, look up Andrew Rodriguez at http://www.fixmyvw.com for lots of your vw / tdi needs.
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Old 11-11-2015, 12:06 AM   #8
loganp
 
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Anyone have a lead on a good cheap turbo back exhaust? Most kits I find are cat back, some are full exhaust but no down pipe, and the ones that are full exhaust with the down pipe are stainless and cost $600! Good ol aluminized exhaust has never failed me on my pickups, I'd think it'd be fine on a car if I could just find one that was a full kit
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2004 Dodge QCLB, '97 12 valve Cummins swap, NV5600, 4x4
BHAF, 4" exhaust, pump mods, Southbend 3600

1999.5 VW Jetta TDI, 5 speed
Panzer skid plate, Profi Diesel 2.5" exhaust

1994 Dodge SCLB, 12 valve Cummins, auto, 4x4
BHAF, 3" straight pipe, pump mods
 
Old 11-12-2015, 11:13 AM   #9
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Welcome to the small block of the TDI world, like previously stated, delete the EGR and clean the intake. You have a TDI with the 10mm VP37 pump, it's actually a reliable pump and is more like a VE pump than the VP44. And like Swole said, Andrew is a good source for parts. So is Peter at idparts.com If you want, you can make a peppy and affordable car that gets great mileage. Or if you get too carried away, you can build these things up to 300 or more hp.

Install a downpipe and take it to a local exhaust shop, the should be able to fab up and install the rest for 100 dollars. This is the one I used on my '03 back in the day.

http://www.idparts.com/downpipe-a4-p-1173.html

Rocketchip, Malone or Kerma are the tuners to go with. Rocketchip is hard to get a hold of, but Jeff is a true genious. I've had good luck with Kerma tuning and Malone is probably who I'll go with for my common rail.

The stock clutch and DMF held together on my old one with 160-180 hp and around 300 lb/ft of torque for a couple years, a lot longer than anyone said it would. However, the DMF came apart. The clutch replacement isn't that difficult or expensive, a G60 SMF with a VR6 clutch is just under 400, a South Bend clutch is recommended for big power. However, the stock clutch should hold up to a tune and injectors.
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Old 11-13-2015, 12:06 AM   #10
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Thanks, that's a good chunk of information!
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2004 Dodge QCLB, '97 12 valve Cummins swap, NV5600, 4x4
BHAF, 4" exhaust, pump mods, Southbend 3600

1999.5 VW Jetta TDI, 5 speed
Panzer skid plate, Profi Diesel 2.5" exhaust

1994 Dodge SCLB, 12 valve Cummins, auto, 4x4
BHAF, 3" straight pipe, pump mods
 
Old 11-13-2015, 08:54 AM   #11
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Stock clutches really vary across the board. I have seen them slip with injectors and a tune and I have seen others last a while with the added power. If you are going to do a clutch upgrade make sure you go to a single mass flywheel as the DMF can cause some serious damage when it fails.

Your ECU being a 99.5 will need to be sent out and socketed for the tune. The 99.5s also had ECU programming that can cause hard starting when warm. A tune will cure this issue as well.

DO NOT WASTE YOUR MONEY ON AN INTAKE. YOU WILL GAIN NO POWER OR FUEL ECONOMY. With that out of the way if you have it burning a hole in your pocket go ahead. I currently run a stock airbox on my car with much larger injectors, 11mm pump and a 17/22 turbo. Your MAF will thank you for the proper filtration and the cold air the well designed factory airbox provides. I would also recommend cutting out the "Snow screen" at the very front portion of the inlet tube that feeds the airbox.

Many people just straight pipe the factory exhaust and gut the cat. A 2.5" downpipe and a shop installed exhaust as above mentioned will work good, too. I personally like the whistle a stock turbo and stock diameter exhaust piping provide - you lost some of this with the 2.5"

I would personally just start with an exhaust, tune and a set of injectors. Injector sizing depends on your goals - tell us a bit more and you can get good suggestions.


I use Mike at TD Tuning for my car. Car runs clean, get great mileage and makes great power.
 
Old 11-13-2015, 10:51 AM   #12
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I will agree with drew on the intake. there is no power to made additionally with it. I simply bought one for the simplicity and the ability to reuse.
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Bagged 00 Jetta big turbo TDI - DRTY DZL
Bagged 03 Jetta Wagon TDI - DALY DZL

07 Dodge Ram Dually 12v swapped g56 - HULN DZL

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Old 11-13-2015, 11:08 AM   #13
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I ran a tune and both .216s and .205s (swapped from the .216s to .205s) on a stock clutch AND DMF on my ALH for the last 130k, I don't drive like a D bag, but that clutch has served me quite well.

I am at 280k, I've rebuilt 5th gear once, on my third timing belt, did all the coolant orings, 3rd alternator pulley, lower rad hose once, EGR delete done and manifold cleaned, 3rd starter, second set of glow plugs. I think that's about it.

I have a BRM I just bought too, I love my ALH too much to get rid of it though!
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Old 11-13-2015, 07:28 PM   #14
loganp
 
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More good information, thanks guys! I was looking on the Malone page, they had something that intrigued me, they have the option for what they call Dynamic EGR. The EGR functions normally until 90* coolant temp, then they shut it off. This is to help the car warm up in colder weather better, but once cruising it acts like the EGR has been removed. Has anyone tried this? Any of you guys with EGR deletes have issues warming up in the cold? It can get into the teens and single digits here quite often during the winter.
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2004 Dodge QCLB, '97 12 valve Cummins swap, NV5600, 4x4
BHAF, 4" exhaust, pump mods, Southbend 3600

1999.5 VW Jetta TDI, 5 speed
Panzer skid plate, Profi Diesel 2.5" exhaust

1994 Dodge SCLB, 12 valve Cummins, auto, 4x4
BHAF, 3" straight pipe, pump mods
 
Old 11-13-2015, 09:24 PM   #15
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Although my temps aren't nearly as cold as you see, I have no problem heating up with my egr not working. A few weeks ago we had an Arizona cold front..... I saw 38 when I left the house, I was at 190 on the temp gauge about 7-8 mile's down the road.
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Old 11-14-2015, 06:32 PM   #16
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I have seen no slower warmup without EGR (cooler deleted too), it's fairly slow regardless of setup.


Sent from my flashscan v2
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Old 11-15-2015, 12:50 AM   #17
loganp
 
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Just won an eBay auction on a ProfiDiesel 2.5" Stainless constant diameter turbo back exhaust with what looks like a resonator or flow through muffler, no cat. $259.87 American with $82.53 American in shipping, grand total $350.69 American. Way cheaper than Buzzken or Kerma! Looks like good quality, hope it is but it is coming from Bulgaria, if not I have a buddy who can TIG stainless.
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2004 Dodge QCLB, '97 12 valve Cummins swap, NV5600, 4x4
BHAF, 4" exhaust, pump mods, Southbend 3600

1999.5 VW Jetta TDI, 5 speed
Panzer skid plate, Profi Diesel 2.5" exhaust

1994 Dodge SCLB, 12 valve Cummins, auto, 4x4
BHAF, 3" straight pipe, pump mods
 
Old 11-15-2015, 11:12 AM   #18
huntduck
 
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So you spiked my curiosity! I looked them up.....it does look like good quality. They have a 100% rating on ebay......if that means anything. Hopefully they have another for bid! I NEED IT! lol
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2006 Dodge 2500 Megacab, 2" level w/35" tires, AFE intake, 5" TBE, 50hp BMS sticks, FASS 150, EfiLive

2002 VW Jetta TDI, bone freak'n stock
 
Old 11-15-2015, 12:08 PM   #19
loganp
 
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Same kit, the auction on this one ends tomorrow. http://www.ebay.com/itm/262140666901 What's funny is they had shipping listed as C$110 for mine which is $82 US, but on this one they list shipping as $110 US lol. But if you get on there and eBay snipe it right at the last second like I did, I bet you can still come out way ahead of the other kits.
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2004 Dodge QCLB, '97 12 valve Cummins swap, NV5600, 4x4
BHAF, 4" exhaust, pump mods, Southbend 3600

1999.5 VW Jetta TDI, 5 speed
Panzer skid plate, Profi Diesel 2.5" exhaust

1994 Dodge SCLB, 12 valve Cummins, auto, 4x4
BHAF, 3" straight pipe, pump mods
 
Old 11-15-2015, 12:24 PM   #20
huntduck
 
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Quote:
Originally Posted by loganp View Post
Same kit, the auction on this one ends tomorrow. http://www.ebay.com/itm/262140666901 What's funny is they had shipping listed as C$110 for mine which is $82 US, but on this one they list shipping as $110 US lol. But if you get on there and eBay snipe it right at the last second like I did, I bet you can still come out way ahead of the other kits.
Thanks! I'll have to setup an account so I can watch it.
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2006 Dodge 2500 Megacab, 2" level w/35" tires, AFE intake, 5" TBE, 50hp BMS sticks, FASS 150, EfiLive

2002 VW Jetta TDI, bone freak'n stock
 
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