Project Hyper Miler Jetta MKIV TDI Part 4, Upgrading the Turbo with Garrett

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After installing the injectors and bleeding the lines, it was time for more dyno testing!

Here we see our first real gains, with the injector nozzles complementing the higher airflow of the Garrett GT1749V we are now getting 89.4HP and 142.6FTLB. Pretty good for not even being tuned yet!

For the ECU tuning, we turned once again to KERMATDI. Their Q-PRO flash programmer is a standalone, menu driven programmer, about the size of a paperback.The Q-pro is convenient and very simple to use. It stores your stock factory tune and up to two modified tunes, it connects to the diagnostic port on your vehicle for communication with the ECU. It also reads and clears Diagnostic Troubleshooting Codes, and it’s easy to return to stock programming at any time, should the need arise. After they sent it to us, we used it to pull the stock file out of the ECU and emailed it back to Kerma. They then emailed us the file optimized for our injectors and turbo to load once we were ready.

Here is the Kerma TDI programmer plugged in to the car. The simple touch screen is easy to use and it starts loading the new file after a couple of prompts from you.

Almost done! The whole process to upload a new program to the stock ECU took about 5 minutes.

We also had to install a 3BAR MAP sensor. BAR is the metric equivalent of PSI, and MAP is Manifold Air Pressure. The MAP sensor is located behind the passenger side headlight in the intercooler piping.  The tune required the 3BAR MAP sensor, and Kerma warned us not to install the sensor before we tuned the ECU lest we fry the ECU. You can be sure we wrote that one down!

This is the run after the Kerma tune, but before the final fuel system adjustments. 116.2HP and 202.5FTLB! We did all of these runs on the same day, and after the tune, you could see the Jetta really jump on the dyno when the boost hit.

Finally, we needed to adjust the injector pump timing and the fuel IQ (injector quantity). Since we’re the only people who work on modern VW’s and don’t own a VAGCOM cable or have VCDS, we took a trip to Modern Specialists in north Long Beach after installing the MAP sensor ourselves. Once at Modern Specialists, the capable hands of Ralf quickly adjusted the injector timing, and then moved on to the IQ.

Here Ralf uses VCDS to check the IQ.

Here you can see the injector value, 12.0mg/str. Since we’re looking for a value between 2.5 and 5, we have a long way to go. Get out the hammer! Seriously!