Hi everyone, I've been lurking on this site and others for a while, and I've learned an immense amount, thank you!

I have the below VW, and 3 BMW's ranging from MS41 to MS42 2.5L to 3.2, planning to play with soon.
However the VW was easier to begin with, after spending about 3 weeks reading and understanding what each map does.


1. Car: 2003 VW Jetta TDI USA model (Bora), with the 1.9 ALH (last year for this engine). 90hp stock, 5 Speed manual. Nearly every piece of mechanical maintenance done.

2. HW Modifications: Fratelli Bosio PP520 Nozzles (similar to ASV 110hp engine nozzles, +~20hp +~50 Nm torque), G60/VR6 Clutch and flywheel upgrade, removed catalytic converter. Stock VNT15 turbo, stock sidemount intercooler.

3. Tuned ECU with VAGEDC15 Suite, flashed with MPPS. Some data logging with VCDS.

I first began with an ASV tune, copied what I believed was relevant, and I've been raising fuel and turbo maps (manual codeblock only) based on some of the theoretical math calculations (aiming for no richer than 1:17), and keeping the turbo under 1170mbar.


I know I probably have to fine tune some of the maps, as I've been doing, and re-flashing, but would like to know which ones I can do.

ALSO, very important, how safe is this? The car works great, low smoke (slight haze at WOT), loads of torque, and much more power, but I don't want to be risking too much.

One more question, about the boost limiter map (by atmospheric pressure), the original was a flat map at 2150mbar, even at high altitudes (lower atmospheric pressure) still the same. I edited mine for the 900, and lower to limit the amount of theoretical boost at higher altitudes. I drive from sea level to 3000+ meters a few times a year with it, and wouldn't like to damage turbo.



Eager to hear criticism, and/or help in improving.

Thanks in advance.

Put original file too.

Apologies. Attached is Original.





NEWEST VERSION BELOW
I also edited my file from above a little more, as I saw that my torque limiter at low RPM was set a bit too high (in my opinion). I scaled down the target boost at lower IQ. I also went back to original N75 duty (unless I get overboost, will be logging with VCDS) following some advice on this forum. My version 1.38 is attached below





As always, Thank you in advance!

juice wrote:Put original file too.

What area in Romania are you from? I was in Cluj for 6 years, finished medical school there. Seeing all the VW tdi's there made me get one here in the states. They're very rare here, hardly any diesel ones around.

I`m from Zalau.

You can make some adjustments. You can keep max fuel iq from 2000 to 4000 rpm, dont decrease it. About smoke limiter, was fine if your nozzles were original, now actually 45 mg are maybe 55 mg(you cant be sure) and maybe in this moment you have smoke.
Go with turbo pressure with 2200 mbar from 2000 to 4000 rpm, max turbo limiter 2250 , also flat it to 2250 in Patm limiter.
You can try also to copy N146 voltage map from 1.9 ASV. Because of bigger nozzles, now the fuel is injected faster , you need to low voltage(less duration, bigger flow)

juice wrote:I`m from Zalau.

You can make some adjustments. You can keep max fuel iq from 2000 to 4000 rpm, dont decrease it. About smoke limiter, was fine if your nozzles were original, now actually 45 mg are maybe 55 mg(you cant be sure) and maybe in this moment you have smoke.
Go with turbo pressure with 2200 mbar from 2000 to 4000 rpm, max turbo limiter 2250 , also flat it to 2250 in Patm limiter.
You can try also to copy N146 voltage map from 1.9 ASV. Because of bigger nozzles, now the fuel is injected faster , you need to low voltage(less duration, bigger flow)

So as I understand it, when I request 45mg IQ, my injectors are providing somewhere around 55mg IQ actual? My smoke with the current settings is acceptable.


The atmospheric Pressure limiter is supposed to be FLAT? Original was flat for all Patm at 2150, including Patm 600 and 700. Isn't this making the turbo put way more than maximum sustained capability at low Patm?

I found my pump voltage map at 054470 and 074470 ... I think the first one is for manual and second for auto. I don't know how to make sure. All the automatic maps are +020000 it seems.

I copied the ASV pump voltage N146 map (all the HEX values, not decimal, because I can't set my scaling in VAGEDC15 suite) from ASV address 0781B6 to my map at 054470.

Here is version 1.39. I have not flashed this one yet. I hope I don't have too much power and kill my clutch.

Everything still safe?



I can turn down some of the 50mg IQ if my injector nozzles are putting ~60mg.

Yes, with bigger nozzles X quantity in reality means more fuel. Flat limit i mean starting from ~850 Pam not under.
Simple and strong stage1 must look like this:
Fueling from 2000 to ~4000 with 51 mg and 2200 mbar pressure. Maybe start from 2250 to save the clutch , avoid too much fuel in low rpm. IF you look at original file you`ll see that maximum fuel is from 1750 to ~2250..well keep it here low and increase to max from 2250 to 4000. If you see too much smoke then youe 51 mg maybe is 55+ or 60.
Log air mass and tune smoke map like this : put 900 with 50 on last column...and dont push too much this turbo, maybe maximum 2250 but not more. Also log turbo spikes, if they appear tune n75 map, open turbo vanes starting with 10%.(25 value means closed, and 70 means opened..well must open to 75 or 80)

juice wrote:Yes, with bigger nozzles X quantity in reality means more fuel. Flat limit i mean starting from ~850 Pam not under.
Simple and strong stage1 must look like this:
Fueling from 2000 to ~4000 with 51 mg and 2200 mbar pressure. Maybe start from 2250 to save the clutch , avoid too much fuel in low rpm. IF you look at original file you`ll see that maximum fuel is from 1750 to ~2250..well keep it here low and increase to max from 2250 to 4000. If you see too much smoke then youe 51 mg maybe is 55+ or 60.
Log air mass and tune smoke map like this : put 900 with 50 on last column...and dont push too much this turbo, maybe maximum 2250 but not more. Also log turbo spikes, if they appear tune n75 map, open turbo vanes starting with 10%.(25 value means closed, and 70 means opened..well must open to 75 or 80)

Thank you for the excellent info.

My last tune with the pump voltage values from the ASV was NOT good (version 1.39 BAD). The car was very underpowered and didn't drive very well. Also I got one boost spike sending the car to limp mode with the original N75 map.
So I raised the N75 map at higher RPM area by about 8%, and now it is not spiking.


Here is my latest tune with stock ALH N146 voltage map, 2162mbar max boost, 50mg max fuel (2000-4000rpm), N75 +8% at high end, EGR off.
This is my favorite so far. Would someone please be so kind to evaluate if it is still safe? This Bora is not my racecar, I have other cars for that.




It is installed on the car for testing. It behaves very well, low smoke - light gray haze, and plenty of power. It is just as fast in a straight line as my friend's 2003 Honda Civic Si (160hp, 1245kg, 0-100km/h 7.5sec). Uphill my Bora/Jetta is faster due to torque.