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850 tdi upgrade project

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Old Jan 21st, 2015, 10:16   #21
martin_r_smith
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Is yours an auto?
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Old Jan 21st, 2015, 19:33   #22
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Manual.

Got other problems too, I'm talking with ron about it, so easy enough to sort. Basically no matter the maf setting with power anything over 50/60% and even very light throttle (less than 7% pedal) you get a serious surge at 1400/1500rpm depending on maf value, which in 4th 5 the is notable but not a problem, 1st 2nd the engine pretty much self drives itself, dicey on ice!
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Old Jan 21st, 2015, 20:10   #23
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Manual.

Got other problems too, I'm talking with ron about it, so easy enough to sort. Basically no matter the maf setting with power anything over 50/60% and even very light throttle (less than 7% pedal) you get a serious surge at 1400/1500rpm depending on maf value, which in 4th 5 the is notable but not a problem, 1st 2nd the engine pretty much self drives itself, dicey on ice!
Interesting, at 75 I'm using a whole 1 psi.

I used to get that with my box, I figured it was just receiving the signal to turn on and then increasing the fuel hence the noticeable surge.
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Old Feb 16th, 2015, 21:07   #24
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Little update.

Things were going very well with the new setup, good power with a nice delivery aimed at reducing low down torque (to save the flywheel), but as with all tuning a few issues have come to light!

The biggest issue being the fact I'm lifting the head off the block at high boost pressure (~26psi). This causes a rush of gas into the coolant system and a rapid overflow of the expansion tank due to the high pressure. Under normal driving (low boost) conditions everything is fine, so to begin with I'm going to just replace the standard 10.9 grade head bolts with stronger 12.9 items. They will be torqued down higher than usual too. If It continues to leak then the head gasket may be damaged so I will replace it as it's not a difficult job.

On a plus note as we were using the rolling road at the time we could react immediately so minimal damage has been done, so a simple bolt change and re-torque should be fine.
I did get a some power figures before the lift and things are looking promising!
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Old Feb 16th, 2015, 22:33   #25
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The t4 guys and previous folk have mentioned head bolts and rod bolts being an issue with higher states of tune being reached. Hopefully that's all!
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Old Feb 16th, 2015, 22:35   #26
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Heads lifting!! Just shows how strong the bottom end on these AEL's are (With uprated Mains bolts!)! I think you've got a great project going there, Ace to read about diesel tuning, Keep it up mate.
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Old Feb 16th, 2015, 22:47   #27
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The good folks over on D24T.com seemed to rate ARP stud kits for keeping the heads snug when running oodles of boost.

A quick gander at the website suggests they come in at ~$145.
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Old Feb 16th, 2015, 22:48   #28
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Originally Posted by brickman View Post
The t4 guys and previous folk have mentioned head bolts and rod bolts being an issue with higher states of tune being reached. Hopefully that's all!
Rod bolts are ok, it's the main bolts that hold the crank in that are the problem. Again they are only 10.9 class as standard but easily changed to 12.9's by removing the sump (hence my shiney sump!) and changing them one at a time.
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Old Feb 16th, 2015, 22:52   #29
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Quote:
Originally Posted by martin_r_smith View Post
Little update.

Things were going very well with the new setup, good power with a nice delivery aimed at reducing low down torque (to save the flywheel), but as with all tuning a few issues have come to light!

The biggest issue being the fact I'm lifting the head off the block at high boost pressure (~26psi). This causes a rush of gas into the coolant system and a rapid overflow of the expansion tank due to the high pressure. Under normal driving (low boost) conditions everything is fine, so to begin with I'm going to just replace the standard 10.9 grade head bolts with stronger 12.9 items. They will be torqued down higher than usual too. If It continues to leak then the head gasket may be damaged so I will replace it as it's not a difficult job.

On a plus note as we were using the rolling road at the time we could react immediately so minimal damage has been done, so a simple bolt change and re-torque should be fine.
I did get a some power figures before the lift and things are looking promising!


How in the hell is the head "lifting" ??? That thing is bolted down with stupid amounts of torque isn't it ? You don't mean to say the head is flexing right ?

Love this thread btw.

P.S. You REALLY need to give us a video of this beast, hope I've not missed one ?
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Old Feb 16th, 2015, 22:53   #30
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Quote:
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The good folks over on D24T.com seemed to rate ARP stud kits for keeping the heads snug when running oodles of boost.

A quick gander at the website suggests they come in at ~$145.
They are good but I wanted to still use a proper 'stretch bolt' rather than the arp's. Main reason is to still keep a kind of fail safe incase I push things to far. I'd rather it lift the head again than completely sh1t itself!
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