High Power Golf 3 1.9TDI Tuning

Hi there all!

What is the best way to approach tuning a high power VW TDI? I need advice in tuning for bigger nozzles and fuel delivery. I have 0.260 Nozzles and 10mm bosch (diesel) pump, K24 turbo (~200hp capacity), big intercooler, etc. I know how to tune boost and everything else but what i want to know is how to tune fule delivery properly with my setup as I'm going to run 1.9bar (~27psi) of boost. How to max out nozzles correctly to get maximum power with as little smoke as possible?

That's not an engine that I've had any experience with but the tuning process will still be applicable. You're going to want to start by modifying your main injector pulse width table to account for your larger nozzle size. Do you have a percentage increase that these larger nozzles will provide over stock fuel flow? A good way of getting in the ballpark is to simply modify the entire table to account for the change in injector size. This compensates for the new injectors so that the ECU can provide the correct pulse width to achieve the desired fuel delivery.

From here the general process is to run as much fuel pressure as you can get away with under high load and add fuel and adjust timing until you've got everything optimised. I'd suggest starting with a target of about 50% fuel delivery BTDC and adjust from there to see how the engine responds.

Ok Andre, thanks. Percentage increase is 76%, ok so i need to calculate that and try to run. I have just made some ''base'' map and made 160hp with lot of smoke :) i need less smoke and more power... i need to clean and retune the map

10mm pump may struggle a bit with those injectors. Your best bet is to join ECUconnections - lots of info on tuning these motors and adjusting the Pump voltage map to get the injectors dialed in.