MK5 TDI 105 DSG :- 300-350hp Build :)

[JamieSmeatonVW]

So I thought I’d post a bit about my Golf build. At the moment it’s a bog-standard BLS 105 1.9 TDI DSG 🙂

To start with, a quick health check: it’s on 200k miles, I’m the third owner, and it’s had a full service including DSG service, wheel bearings, brakes, inner tie rods and ends, and ball joints. That’s about it maintenance-wise.

My plan is to have a 3" downpipe made up, retaining V-band fitment. I’ve ordered a GTD2060VZ off eBay. I’ve got an old GT1749VA which I’ll cut up and use the manifold from to chop and weld the GTD to. I just need to order a 3" V-band and a braided oil feed. For the oil return, I’ll probably make something up with a barb fitting and a 90-degree silicone, as I did that on my Fabia GTB build.

Next, I’ll be sourcing an ASZ (PD130) or ARL (PD150), ordering a new BLS rear main seal and a new DSG flywheel, plus a needle bearing. I’m planning on fitting Maxpeeding rods with new main and crank bearings. I’ll check the crankshaft for imperfections and make sure it’s within tolerance.

I’m debating either an SDI camshaft or a 272 Piper (9.8mm lift). I’ll more than likely spend time porting and opening up the head to improve flow. I’ve also got a tool I made to bowl the piston combustion chambers out to 43mm.

Next on the list is Firad injectors. I’m weighing up whether to send mine off to be checked and, if they’re good, fit new nozzles and have them calibrated, or just buy a ready-built set. I’ve seen people making injector PD jigs to swap nozzles.

I’ll be retaining EDC16 and doing the block mod so I can run a PD130 block.

I think this will be a solid setup 🙂

[JamieSmeatonVW]

So, another quick post.

I’ve updated the ZF Gen 3 Steering Rack firmware from Early Version 1K0 909 144 C to Late 1K0 909 144 R, so I can change the TTRS Parameter for better weight and feel.

I also updated the ABS module from 1K0 907 379 AP to 1K0 907 379 CE. I really wanted XDL, but it isn’t supported on my original ABS unit—only BL & BG. I think I’m going to fit a BL unit and then update it to CE firmware, as that’s the latest. That way it’ll support XDL, HHC, and more 🙂

So far, I’ve noticed a big difference in the steering. It’s lighter at slow speeds, centres faster, and feels sharper. At higher speeds it’s a lot heavier and more precise—definitely a worthwhile upgrade in my opinion, especially for a software change.

One thing I’ve noticed: when I hold the ESP button, the traction control light flashes. This is after updating from AP to CE. I think this might be full ESP off and stability control disabled, but I’m not 100% sure—either way, it’s a nice upgrade 🙂

[RBS]

Great that you experiment with the wide range of VAG parts👍🏻👍🏻
Keep it up and share some pic’s of your ride and work that you‘ve done😉