MK5 Golf GTI

All Things Mk5 => Members Rides => Topic started by: ryanp on January 30, 2012, 04:20:17 pm

Title: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: ryanp on January 30, 2012, 04:20:17 pm
Hi

Thought I would finally post a build thread on this Forum. I figured you guys wouldn't want to see a dirty diesel on a GTI Forum, but seems like there are a fair few on here.

Back in March I bought a 2007 Jetta 2.0 TDI (BKD Engine). Here are some pics of it when I got it:

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FStandardJetta6.jpg&hash=27c32197fd756a77c2956b19709d58b49ec27f96)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FStandardJetta5.jpg&hash=a0b9bb778a55e79899f577afb8934731ad4133fd)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FStandardJetta4.jpg&hash=f9f1616866eaa61d3c9bde4d89e88e4bb11686bb)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FStandardJetta2.jpg&hash=8f1a61967352c9f61707a7033310f7c25e85a56a)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FStandardJetta1.jpg&hash=e5c395168f3d218716bad8831a249b08c2019b04)
 
First up is the chassis -
 
Audi 18" x 8.5" Fat Fives with 225/40/18 Uniroyal Rainsports
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FFatFives1.jpg&hash=132cd622d974ab0e39733dfb98539bbf61427a3b)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FFatFives2.jpg&hash=d4010337f4e5978f84e76ddbfec83fb088130998)
 
KW V1 Inoxline
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FKWV1s.jpg&hash=4b9099e860b0414e0cc22a5f7ced6d1dc8078473)
 
We also fitted an Audi TT 2.0 TFSI Rear Axle and Alloy Hubs that gave us 26mm more width and TT Front Alloy Hubs and Cast Wishbones, which give an extra 30mm and more camber. I have loads of pics, but didn't upload them. Everything is much beefier and lighter.
 
R32 345mm Front and 310mm Rear Discs. The front calipers have a TyrolSport Caliper Stiffening kit, which I would recommend it to anyone. Google it and see what I mean.
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2F345mmFrBrakes.jpg&hash=bd64f1eb137c0a89172016b096de9689730abb1e)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2F310sKWs.jpg&hash=817c843aa25749a480469c75901cde71320919a9)
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: ryanp on January 30, 2012, 04:20:56 pm
We used Eos 3.2 FWD Splash Guards with fit perfectly with a slight modification
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2F2wd310mmrrShields.jpg&hash=df05f8b90c35cdc978875b3b5cf1462142a2d99a)
 
And it looked like this:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FStance4.jpg&hash=4fba4a62c9e1497b5357cc6f3af79af72bd282cb)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FStance3.jpg&hash=430be7b9baa557031faa36c6366ceb08bbda8a3e)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FStance2.jpg&hash=06756f01b92564cd2d8c1c66559b5d533e5fc8c9)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FStance1.jpg&hash=1827ec192d1495774954e56b20ebc75961cc630a)
 
We then fitted a Darkside Developments EGR Delete and removed the EGR cooler completely:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2Fjetta7.JPG&hash=a0a5b68fc338b29baa40f3b903d5322ca186b0a3)
After we mapped it and took it to the dyno, here were the results:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FJettaGraph.jpg&hash=3dec41a0dc52e0a36e79b7c2207325700082e767)
 
Some little interior mods -
 
Scirocco Flat Bottom MFSW
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FSNV84568.jpg&hash=d201ab9ac53a7b75d362bf3a7cbfd2a972b3bb00)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FSciroccoWheel1.jpg&hash=fdc485b4bb1d75737288e16f1d987a01dd3bc126)
 
Passatt CC Switches
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FJettaSwitches-1.jpg&hash=04b72d89da446151be5c0db04b94ec258a20b3ea)
 
Thats how it stayed for a few weeks, but we had plenty more in the pipeline.
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: ryanp on January 30, 2012, 04:21:46 pm
We then concentrated on the body mods, we did the following:
 
Golf GTi Front bumper with Summer grills
Jetta GLI Rear Valance
Hella Projectors with Lamin-X Gun Smoke Tint and Osram Nightbreaker Bulbs
Smoked Rear Lights
Smoked Reflectors
Smoked Indicator Lenses
Smoked Numberplates
Rolled and Flared arches
Black VW Emblems
 
Here is how it looked:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2F%2Fimages%2Fprojects%2Fjetta%2FJetta%2520%287%29.JPG&hash=cfc7079ab2fcc8ebd80c209bd0a31bc35a700103)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2F%2Fimages%2Fprojects%2Fjetta%2FJetta%2520%289%29.JPG&hash=0bd7a18603231f7d5c11be71ee1c016d1ac96519)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2F%2Fimages%2Fprojects%2Fjetta%2FJetta%2520%2810%29.JPG&hash=d37e1dc6bb4e1dd5f2007edbf06b594b49ed4463)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2F%2Fimages%2Fprojects%2Fjetta%2FJetta%2520%2811%29.JPG&hash=e29565e4d3cedc54968035f3fb64b5cc2746f67f)
 
Next was to fit the Darkside Developments 2.0 16v TDI Turbo kit with a GTB2260VK Turbo from a 3.0 v6 Audi:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2Fjetta6.jpg&hash=a5a48ee8fadd6eea5f48a2dd76b5258d2ee46433)
 
Along with an S3 Intercooler and hard pipe kit (I didn't get a pic of the cooler before we fitted it, but it is all alloy with welded end tanks and no clip connectors):
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2Fjetta8.JPG&hash=4ad28ed626c75614907e4fdf6bbc2362b7929bda)
 
Milltek 3" System (made for a US Jetta GLI):
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FGLITailpipes.jpg&hash=14d4ae9f4696a37b7a7fc2f6c2ecf29821c746ec)
 
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FMilltek.jpg&hash=e576abfe6ae6992ed0fd7f3723e22d935773e5af)
 
We also modified the MAF, as it was deleted from the map:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FModdedMAF.jpg&hash=ab952169cb6b6bf0c4f0921ea798d8c525231688)
 
Then we took it to the same dyno so see what we were making
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FJetta%2520Stock%2520%2B%2520Mapped%2520%2B%2520235.jpg&hash=e7caf0e018eca70731bbd123a446cf75e3a38fc9)
 
235.3BHP and 330Ft/Lbs. This is on a very conservative dyno (the operator calls it the 'heartbreaker') with ZERO smoke and a very road friendly tune. 3 days after fitting the turbo I drove 1500 miles to, from and around Cornwall and averaged 57mpg for the whole trip. It didn't skip a beat.
We still have some adjustment in the stop screw to get the boost to come in a little earlier, but it still pulls very well from low RPMs. What you lose at the bottom end is nothing compared to what you gain at the top end, it pulls like crazy to the 5000rpm fuel cut we have in the tune and pulls 130mph in 5th easily. I have found the 140mph electronic limit though, which we are working on removing ASAP!
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: ryanp on January 30, 2012, 04:22:26 pm
Next on the agenda are a Sachs SRE Single Mass Flywheel and Sintered Paddle Clutch, Peloquin Limited Slip Differential, fitted to a low mileage PD170 Long Ratio Gearbox
 
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2FSREClutchFW.jpg&hash=fa45032fcaafdd8a1bcd929d1cf93538784f61c5)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fdarkside-developments%2FJetta_2L_16v_TDI_BKD%2F02QPeloquin2.jpg&hash=c7bf6173cf72a4dcf844b6f374b787004dbd9b12)
 
Someone on the Edition 38 forum posted up a pic of the Jetta at their show:
 
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fc332%2Fandy_cull%2FDSC01180.jpg&hash=e575e972e51a6c6393dd32e465d275c103519b9b)

We then fitted the Sachs SRE Single Mass Flywheel and Clutch and a PD170 Long Ratio Gearbox with a Peloquin LSD Installed. We also strengthened the shifter forks so we can do some fast changes. Once the clutch was run in, a set of Race PD Injectors was dropped in.

Here are the results from this afternoon:
 
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FJetta%2520299%2520%2B%2520300%2520%2B%2520301.jpg&hash=acd76f1c4efa607963babae081467e81436d31f7)
 
We did 3 pulls and they were all pretty close together, the best run was 301hp and 440Ft/Lbs.
 
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FJetta%2520301%2520%2B%2520235%2520%2B%2520166%2520%2B%2520134.jpg&hash=1f55f4c4b7b7c811850cfcbf328a3772d9006d97)
 
And here is a graph comparing the stock power to now, we have made pretty good progress!
 
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FJetta%2520301%2520%2B%2520134.jpg&hash=1587c7505c156a6e946e410d41256762576dea90)
 
Here is the spec we have now:
 
2.0 16v BKD PD140 Engine
Darkside GTB2260Vk Turbo Kit with Tubular Manifold and 3" Downpipe
Darkside Race PD Injectors
Darkside FMIC Kit with S3 Intercooler and Alloy Pipework
Darkside EGR Delete Race Pipe (Retaining ASV)
Milltek 3" Non-Resonated Exhaust System with Twin 76mm Jet Silencer
Darkside Developments Re-Map with MAF and EGR Delete
 
301BHP & 440Ft/Lbs – Dyno Proven
 
PD170 BMN Long Ratio Gearbox
Peloquin Limited Slip Differential
Sachs SRE Single Mass Flywheel with Sintered Paddle Clutch
Polyurethane Filled Dog Bone Bushes
Darkside Developments Short Shift and PU Filled End Links
 
R32 Front Brake Calipers
R32 345mm x 32mm Brake Discs
Genuine Audi S4 Front Pads
TyrolSport Caliper Stiffening kit
R32 Rear Calipers
R32 310mm x 20mm Rear Brake Disc
Genuine VW Rear Pads
Eos 3.2 FWD Rear Splash Guards
Silver Zinc Plated Calipers
 
KW V1 Inox Coilovers
Audi TT Front and Rear Top Mounts
Audi TT Alloy Front Wishbones with Solid Bushes and Adjustable Ball Joints
Audi TT Alloy Front Hubs and Alloy Track Rods (26mm Wider Track)
Subframe Spacer Kit
Audi TT Driveshafts
19mm Front ARB
Audi TT Rear Axle with Alloy hubs (30mm Wider Track)
Passat R36 21.7mmx3.6mm Rear Anti-Roll bar
 
Audi A8 ‘Fat 5’ 18”x8.5” ET45 Wheels
Uniroyal Rainsport 2 225/40/18 Tyres
Genuine VAG Wheel Bolt Caps
18" Spacesaver Spare
 
Hella Projectors with Lamin-X Gun Smoke Tint and Osram Nightbreaker Bulbs
Smoked Rear Lights
Smoked Reflectors
Jetta GLI Rear Valance
Rolled and Flared arches
Black VW Emblems
 
Leather Sports Seats
Scirocco R / Golf IV Multifunction Steering Wheel
Scirocco Headlight, Mirror and Window Switches
I-Pod Adapter in Armrest
 
Next step is a cam, headwork and bigger injectors. All of which are difficult to source, but I will find them!

Any questions, please don't hesitate to ask!
 
Thanks
 
Ry
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: ryanp on January 30, 2012, 04:23:45 pm
The results from GTI Festival at Santa Pod last year:

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fcc394%2Fdarkside-developments%2FJettaSantaPod2.jpg&hash=27c0677946dadb98d22a4fc201364d26aeafaeae)

We had been down at Santa Pod all day today taking the Jetta up the strip. I managed to put in exactly 20 runs back to back without even a hiccup! All the runs had a terminal speed of over 100mph even when I selected reverse or had the odd missed gear!! As this was my first time out drag racing launching was the main issue so there are still a few tenths to gain and a less corner friendly suspension setting might help too but I’m happy as it’s exactly as it drives on the road!

The best run was a 13.8419 and the best terminal speed was 105.43mph. AFAIK the Fastest FWD TDI of the day.
We missed the fastest TDI trophy by 0.4 sec. That went to a nice guy with a homebrew Mk2 Golf Synchro/Haldex sporting a PD150 Lump, Hybrid Turbo and 150bhp shot of Nitrous!!

Here are two slips:

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fcc394%2Fdarkside-developments%2F138419Sec.jpg&hash=c8d610bd6a5bd9cd2e5f1649494b4f7c300e3064)
 
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fcc394%2Fdarkside-developments%2F10543mphTerminalSpeed.jpg&hash=919e2abe39f7b35687e5a480d94d4fd5f137b0a0)

YouTube of the Jetta:



That was a 14.4 @ 103mph.

Hope you like it!
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: Andy on January 30, 2012, 04:23:54 pm
As said on the other forum--awesome car :notworthy:hopefully all been well,come next year i will be buying a darkside turbo for mine if my car behaves itself
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: ryanp on January 30, 2012, 04:25:56 pm
We took the Jetta to Shark Performance in Mansfield yesterday to an Open Dyno Session.

They use a BaPro Dyno so we thought it would be good to compare how the Jetta performed against the DynoDynamics we use on a regular basis.

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FJetta%2520301%2520%2B%2520134.jpg&hash=1587c7505c156a6e946e410d41256762576dea90)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FJetta%2520299%2520%40%2520Shark.JPG&hash=cd814dc3fa5328e7dfb3805427fed4564b231966)

301.2bhp and 440Ft/Lbs - DynoDynamics @ John Sleath
299.5bhp and 438Ft/Lbs – BaPro @ Shark Performance

Difference is ~0.5% overall so I would say our results are accurate :)

Cheers

Ry
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: GTsport on January 30, 2012, 04:32:01 pm
Seen this car on Darksides website - amazing stuff  :notworthy:

Absolutely love the Audi fat fives  :party:

I shall be back later to have a proper read!


 :happy2:

Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: ryanp on January 30, 2012, 04:36:31 pm
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FNSNPJetta%2520%281%29.jpg&hash=96e32f1f953c2cb642acbd2d63b565375e790acd)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FNSNPJetta%2520%283%29.jpg&hash=ab4c4c9d33a6cde1c5b9cebc8827adc05f6b360c)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FNSNPJetta%2520%284%29.jpg&hash=ed6386a0b646dfcfdb1ef1f7904a146ab4cc84fc)
 
Bit of an arty shot for you:
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FNSNPJetta%2520%282%29.jpg&hash=abc316728378ec27c497219999194b6ea14fd11d)
 
Big thanks to Adam and Tom at No Smoke, No Poke .com (http://"http://www.nosmokenopoke.com/") for the pictures. We will have a full company feature on their website when it is launched mid Feb.
 
We will also be attending the Charity Dyno Day / Car Show at Thor Racing in Coventry, it would be great if any of you guys could attend!
 
For the eagle eyed you will notice the Front Bumper has been painted as well as the rest of the bodywork, same colour as before but it looks like a completely different car! Also got some Audi S4 Avus Wheels in Hyper Black (thanks Metal Magic of Barnsley (http://"http://www.metalmagicwheelrefurb.co.uk/")). We fitted the Jetta GLI Sideskirts as well.
Plans for the bodywork are the vehicle wrap the chrome around the windows (decided against painting it) and we will also fit a textured black from splitter as I think there is too much blue on the front now.
 
We put some SuperPro Console Bushes, set up for increased Castor and then took it to Russ at Mick Gardner Racing (http://"http://www.mickgardnerracing.com/") for setting up. All we can say it WOW, Russ is a genuis when it comes to setting up suspension, as well as being an Ohlins Suspension Dealer, he sets up cars for a lot of big name companies and race teams so knows his onions (theres a Spring Onions joke in there somewhere!). I would recommend anyone to go and see Russ if you want your car to handle how it should!!
 
We also have a complete new interior which should turn a few heads, its not 100% finished yet though, waiting on a fancy new gearknob from Germany and then that, the handbrake handle and armrest cover are going to MJ Interiors for a 'freshen up'. I will post up pics when it is finished.
We also have all the ingredients for some more power so keep your eyes peeled for some more updates!
 
Thanks
 
Ry
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: Sunglasses Ron on January 30, 2012, 04:37:35 pm
Sleeper.com  :grin: Great work  :congrats:
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: mortygttdi on January 30, 2012, 08:37:00 pm
Just like to say if anyone has any worries about buying or having any work done by Scott and Ryan then don't they are the best set of lads at Darkside I have come across top lads :happy2:

Darren
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: Phil Miller on January 30, 2012, 08:46:53 pm
Great stuff, so when my turbo goes bang i will be knocking on your door, great car mate :happy2:
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: Andy on January 30, 2012, 08:48:41 pm
Cheers of the heads up Darron :happy2:
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: mortygttdi on January 30, 2012, 08:52:31 pm
Still not been in the Jetta I always seem to go over when its raining :signLOL:
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: Andy on January 30, 2012, 08:56:29 pm
If you take the jetta out ,its a Good.test drive to my garage :signLOL:
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: mortygttdi on January 30, 2012, 08:58:12 pm
Ho no its Ryans baby is the Jetta mate I wouldn't think of driving it but don't mind getting in the passenger seat.

Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: Andy on January 30, 2012, 09:01:04 pm
Yeah i know mate i was just pulling your leg :signLOL:
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: Tfsi_Mike on January 30, 2012, 09:10:36 pm

Still love this  :love:
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: ryanp on February 10, 2012, 09:04:02 am
Jetta at 4200rpm in 6th, fuel cut is 5200rpm...

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FJetta%2520Clocks.jpg&hash=69318eea5023427fe74fb2774416077953c6af29)

We removed the Electronic Limiter :)
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: mortygttdi on February 10, 2012, 05:02:17 pm
Cheers for today Ryan car feel much better :happy2: I keep fogetting to ask if your going to be doing any thing for VW Festival @ Harewood?? would be good to get a stand there.

Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: NotNormal on February 10, 2012, 07:05:18 pm
This is great, loving your work !!

The only thing I'd want different......DSG ;) :)

Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: ryanp on February 13, 2012, 10:25:44 am
Not too sure Darren, would be an idea I suppose. We would have a few tasty vehicles (not just cars  :happy2:) to put on the stand I suppose.

DSG would be nice. We have a customer in Norway with an Audi A3 DSG fitting one in a few weeks, and a friend is also toying with the idea.

We had the Jetta on Thor's Hub Dyno on Saturday for the NoSmokeNoPoke.com (http://nosmokenopoke.com/) Launch Day.

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FJetta%2520287whp%2520at%2520Thor.JPG&hash=037dfc725ca27eb331d3316f4f6fe10fa47f5b39)

This was with a some mapping tweaks (still not quite finished) but no more hardware upgrades.

We ended up with 287hp and 425Ft/Lbs at the Hubs. If you assume 10% transmission losses (it has been more like 20% on Shark's BaPro Dyno), you are looking at 316bhp and 468Ft/Lbs at the Flywheel.

Can't wait for the mapping to be 100% finished and then we can get the other upgrades fitted.

Cheers
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: Andy on February 13, 2012, 01:14:31 pm
 :notworthy: :notworthy:
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: Matto on February 15, 2012, 08:14:06 am
Have been following updates on this car through Facebook. Very impressive and amzing what can be done with these engines.  :congrats:
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: ryanp on April 21, 2012, 06:15:37 pm
Just as a little teaser, here is the current speclist for the Jetta.


Darkside GTB2260Vk Turbo Kit with Tubular Manifold and 3" Downpipe
Darkside Race 16v PD Injectors
Audi S3 Intercooler
Darkside Alloy Intercooler Pipework Kit
Darkside EGR Delete Race Pipe (Retaining ASV)
External Oil Cooler Kit
EGR Cooler Delete
4 BAR MAP Sensor
Milltek 2.75" Non-Resonated Exhaust System with Twin 76mm Jet Silencer
Darkside Developments Re-Map with MAF and EGR Delete

316BHP & 468Ft/Lbs @ Flywheel
287hp and 425Ft/Lbs @ Hubs

PD170 BMN Long Ratio Gearbox
Peloquin Limited Slip Differential
Sachs SRE Single Mass Flywheel with Sintered Paddle Clutch
Polyurethane Filled Dog Bone Bushes
Darkside Developments Short Shift and Poly Filled End Links

VW Racing 6 Pot Front Brake Calipers
VW Racing 352mm x 32mm Brake Discs
Ferodo DS2500 Front Pads
R32 Rear Calipers
R32 310mm x 20mm Rear Brake Disc
Genuine VW Rear Pads
Goodridge Braided Hoses
Eos 3.2 FWD Rear Splash Guards
Silver Zinc Plated Calipers

KW V1 Inox Coilovers
Audi TT Front and Rear Top Mounts
Audi TT Alloy Front Wishbones with Solid Bushes
Audi TT Adjustable Ball Joints
Audi TT Alloy Front Hubs and Track Rods (26mm Wider)
Audi TT Console Bushes
Subframe Spacer Kit
Audi TT Driveshafts
Stock 19mm Front ARB
Audi TT Rear Axle with Alloy Hubs (30mm Wider Track)
Passat R36 21.7mmx3.6mm Rear Anti-Roll bar

Audi S4 'Avus' 18”x8” ET45 Wheels - Hyper Black
Uniroyal Rainsport 2 225/40/18 Tyres
Genuine VAG Wheel Bolt Caps
R32 18" Spacesaver Spare

Golf GTi Front Bumper with Summer Grills
Jetta GLI Side Skirts
Jetta GLI Rear Valance
Hella Projectors with Lamin-X Gun Smoke Tint
Smoked Rear Lights
Smoked Reflectors
Smoked Mirror Indicator Lenses
Pressed Numberplates
Rolled and Flared arches
Black VW Emblems
Matt Black Wrapped Window Trims

Seat Leon Cupra K1 Bucket Seats trimmed in Bridge of Weir Totem Purple
Rear Seats with Centre Armrest
Doorcards Trimmed to match
Black Alcantara Dash and Door Trims
Black Alcantara Armrest Cover and Handbrake Handle
Golf R Multifunction Steering Wheel
Golf R Gearknob
Passat CC Chrome Headlight, Mirror and Window Switches
VW Santana Chrome Fuel Flap Switch
RNS 510 Satnav with LED Screen
I-Pod Adapter in Armrest

As you can see, we have made quite a few changes since the last time we took any pics or updated the topic.

Pics will be uploaded tomorrow after Santa Pod, or later tonight if we get the detailing finished!

Thanks!
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: Andy on April 21, 2012, 06:19:37 pm
 :congrats:
hopefully if my car stays reliable next year or before--i will be getting yous to fit one of your turbo's :happy2:
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: Tfsi_Mike on April 21, 2012, 06:21:48 pm

How do you find the Peloquin Ryan?  Im a bit underwhelmed by mine
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: vwrascal on April 21, 2012, 07:32:24 pm
 :notworthy:  love it, heaps of torque  :driver:
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: Yawn on April 22, 2012, 12:54:17 pm
Proppa Jetta  :love:
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: Black9 on April 22, 2012, 02:08:15 pm
Impressive for a TDI Jetta, great performance with good MPG :notworthy:
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: Oli on April 22, 2012, 04:53:53 pm
Now that is impressive - jettas are really catching on, and to be fair they are the bargain of the century when compared to the price of a golf!
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: rich83 on April 22, 2012, 05:01:14 pm
This car is ridiculous... saw it today at the pod. Spoke to one of the dark side guys (who was in the caddy), seemed like a nice chap bu no idea who it was. :signLOL:
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: mortygttdi on April 23, 2012, 12:17:24 am
Rich it'll been Scott in the Caddy, Ryan will have been in the Jetta? the Caddy will be in the region of 230bhp or not far off?

Darren
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: ryanp on April 23, 2012, 04:11:18 pm

How do you find the Peloquin Ryan?  Im a bit underwhelmed by mine

I've always been impressed with it TBH, torque steer is non existant and it puts the power down nicely. The Jetta has been set up properly as well, corner weighted etc so that makes a big difference to the way it all feels

Now that is impressive - jettas are really catching on, and to be fair they are the bargain of the century when compared to the price of a golf!

They should do, more space, all the same toys and a few grand cheaper than a Golf!

This car is ridiculous... saw it today at the pod. Spoke to one of the dark side guys (who was in the caddy), seemed like a nice chap bu no idea who it was. :signLOL:

Could have been Me, Scott or Stef. Scott drove the Caddy most of the day, but I did a couple of runs and Stef was sat in it a few times in the queue.

Will post some new pics in a bit :)
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: rich83 on April 23, 2012, 04:21:36 pm
I was talking to said person about the R32 brakes and VW racing kit.... in the queue for the 1/4  :happy2:


Im almost certain it wasn't stef  :signLOL:
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: ryanp on April 23, 2012, 04:33:34 pm
Here are the pics are promised. STILL a work in progress but there are quite a few changes from the last pics. Anyone at Pod yesterday will have got a sneak peek!

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FDarkside%2520Jetta%2520%281%29.JPG&hash=798a0faecc86ab270ac2bed8bc73dd8cb961e406)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FDarkside%2520Jetta%2520%282%29.JPG&hash=a7c22e9c5f9c48514fc3604f3c9159fb4ecaecba)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FDarkside%2520Jetta%2520%283%29.JPG&hash=c7c3f7e1f6a2fef5ef354e94eb8041786cc14cb2)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FDarkside%2520Jetta%2520%284%29.JPG&hash=5f9cc3c6fb47716a05e2c69c3722fd72a4e456ab)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FDarkside%2520Jetta%2520%285%29.JPG&hash=1ac4dd77a02029f770a9282b56a57a02accd6de5)

VW Racing Brakes -
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FDarkside%2520Jetta%2520%286%29.JPG&hash=3dab0e2d03a9ef74492546cbc709f2dd955027fb)

Big Pimping Interior -
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FDarkside%2520Jetta%2520%287%29.JPG&hash=3b77d0545ec035575b924d36cc9d39ddf8213646)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fprojects%2Fjetta%2FDarkside%2520Jetta%2520%288%29.JPG&hash=8e8db2fd8ab096008cf2efab3e0e7b31a220cd5d)

Have 100's of Photos and Videos of yesterday so going to wade through them tonight/tomorrow and get them posted up!

Thanks
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: Banham on April 23, 2012, 10:21:22 pm
I saw this beauty fly up the track at the Pod. Very quick off the the line
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: neil86 on April 24, 2012, 08:55:51 pm
Can't  wait to see this at some point, and I have spoke to you guys over the phone a few times now for help, and you have been great not many places will entertain giving you advice unless your giving them money.
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: OldSpeckledBen on April 24, 2012, 11:22:13 pm
Saw this at the pod on sunday :smiley:, it was amazing to see a diesel doing the 1/4 mile that quick  :notworthy: although the silver Fabia VRS was pretty crazy as well  :smiley:

Keep up the awesome progress,

Ben
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: ryanp on April 25, 2012, 11:42:46 am
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fsantapod22042012%2FJetta%2520%26amp%3B%2520Caddy%2520%40%2520Pod%2520%281%29.jpg&hash=939d2f2e871499d80195fe870da270554f9abc4f)

Also got a load of other photos on the facebook page from Santa Pod on Sunday:
 
Darkside Developments | Facebook (http://www.facebook.com/media/set/?set=a.444042408946665.125480.262413180442923&type=3)
 
Also have a few good videos on our YouTube Channel:
 
Darkside TDI | YouTube Channel (http://www.youtube.com/darksidetdi)
 
If anyone has any more photos of videos, please let me know and I will upload them!
 
Results from the day:
 
Jetta Best Runs - 13.83 @ 104.3mph & 13.90 @ 104.7mph
 
Caddy Best Run - 15.48 @ 89.78mph
 
Regulars at the Pod were complaining of strong headwinds killing their times so we are glad to have (marginally) beat our times from before.
 
We managed to get 12 runs in the Jetta before we had a little mishap, which some people will have seen us pushing the car back over the start line!
 
Here is the damage:
 
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fsantapod22042012%2FSnapped%2520Jetta%2520Shaft.JPG&hash=837e1651877b8c1cf29d74710ba69f55eafcfbdc)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.darkside-developments.co.uk%2Fimages%2Fsantapod22042012%2FSnapped%2520Jetta%2520Shaft%25202.JPG&hash=92d1a45346f4333aa6b03006c0c6e2184b65af2b)
 
Semi Slicks and a massive burnout to warm the tyres up don't go well with the sticky surface! We had a replacement driveshaft with us (always prepared) but the hubnut would not come lose! Ended up getting recovered to our Unit and it was back on the road by 9am on Monday!
 
Also updated the pics on the website for both the Jetta and the Caddy, some nice ones on there!
 
Cheers
 
Ry
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: audiag on April 25, 2012, 08:47:12 pm
Linkys Not workin for me  :sad:
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: ryanp on April 25, 2012, 09:27:46 pm
Sorted
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: sub39h on April 25, 2012, 11:26:23 pm
oh dear, i'd lose that interior but otherwise looks awesome

love those Avus wheels - really set it off
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: mortygttdi on April 26, 2012, 07:08:15 am
I was talking to said person about the R32 brakes and VW racing kit.... in the queue for the 1/4  :happy2:


Im almost certain it wasn't stef  :signLOL:

Rich Stef's a bloke so i'm sure you wouldn't have known :grin:

Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: ryanp on April 26, 2012, 08:27:53 am
Easy to confuse him with a woman though, haha.

I call it the Marmite interior, some people love it, others hate it! I like it cos its different, if it was black leather you wouldn't notice it!
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: rich83 on April 26, 2012, 09:16:20 am
LOL :-)
Title: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: ConorF on November 26, 2012, 06:07:26 pm
Where did you get the GLI valance? I love this car, always have  :happy2:
Title: Re: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: benj1989 on September 05, 2013, 08:36:29 pm
Wow this is amazing. Am soo wanting to get the turbo kit to take my Leon to 220bhp.

Sent from my HTC One using Tapatalk 2
Title: Re: Re: Jetta 2.0 16v TDI - 301bhp & 440Ft/Lbs. Yes its a diesel...
Post by: torque777 on September 05, 2013, 09:04:56 pm
Wow just read this through ..very impressive ..got talking to some of darkside developments lads at inters on tdi sport club stand all seemed very knowledgeable and helpful

sent using my own fingers