iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

[iichel]

So, update time. There has been a lot happening with a good result.

First things first, the car was not driving very nicely since the gearbox had lost its basic setting of the clutch. - P177C.
Since all hardware was new (clutch pack, flywheel, fluids), the hardware was probably OK.

So I had to do a clutch adaptation. It often restores functionality and comfort for a DSG gearbox. Can be done with VCDS:
http://wiki.ross-tech.com/wiki/index.ph ... _(DSG/0AM)





Now it drives like a charm.

[iichel]

The next update is regarding the BAT (Big Ass Turbocharger).
The car had its original turbocharger removed and upgraded to a Garret gtc1549vz (03L253010F); the turbocharger from the 2.0 TDI CR 170hp 'GTD' engine from the Golf 6.
This is a popular plug-and-play upgrade for 1.6 and 2.0 TDI common rail engines, combined with an intercooler upgrade.

Replacing the turbocharger was easy and already done when the engine was still in the donor car.

Now however it started complaining about P2563 - Turbocharger positioning sensor.
http://wiki.ross-tech.com/wiki/index.ph ... 563/009571

The turbocharger is operated via a vacuum line, to change the nozzle geometry and regulate boost pressure.
The positioning sensor (blue) will give feedback about the position, this needs to correlate to the vacuum pressure.



The position sensor is a hall sensor and its signal varies between 0.500V and 3.500V, if calibrated properly. You can read this with VCDS in measurement value IDE04268-ENG102598

In my case, the signal was implausible and the car went into limp mode. The signal at rest was in fact too high; 3.75V.
So it needed to be adjusted. And since VW is German, there are PROCEDURES.
There is no procedure for the turbocharger in question, but there is one for the standard turbo. So let's use that one.
It's described in full here (from ELSAWIN): https://imgur.com/a/cNIUMI1

VW want you to remove the vacuum line and attach a hand vacuum pump like in the picture above and give it -0.65 bar of pressure, absolute.
And then adjust the turbocharger to show a certain voltage, 0.760V in IDE04268-ENG102598.
There is no adjustable arm on the new turbocharger, but you can loosen the bolts and slide it axially:



So I went ahead and applied the procedure with success. But this is very difficult when you don't have such a hand pump.

What I did is switch on the ignition, engine off, and set the turbocharger to 3.40V in rest. This does the trick just fine as well.

The only issue I had left, is that the new turbocharger is very boost-happy, it will give over 3000mbar of pressure and shoot off the hoses from/to the intercooler. For fun.
But for now the car is very driveable, torque is not too high (95hp/250nm according to measurement values)

[ciclo]

Congrats!


Tomorrow? more and better ...

[iichel]

Thank you very much, perhaps this is a good time to confess that I am actually a Hamilton fan

[Thanos]

I have been lurking this forum for a while, I must say I am really impressed what you (and others like ciclo) have done to your cars!

I couldn't imagine the time/money spent and brain cells fried on your projects!

I have one question though, since your car now has the 1.6 TDI, isn't it technically not a bluemotion anymore?

[iichel]

Thank you for your compliments Thanos. Yes, we have a nice group of knowledgeable and helpful members like ciclo and many others (Madwarlock, firegrafik, RUM4MO, CNK, Patil and many others from around the globe) that have done high level modifications to our Polos.

Regarding the Bluemotion part, yes, technically you're right.
However, I'm fairly confident my Polo 6R is one of the few Polo 6R 1.6 TDI DSG's with start/stop system + recuperation (7L6).
Technically, that would make my car the 1.6 TDI DSG BlueMotion Technologies
The 'real' 1.6 TDI DSG in the Polo 6R is a CAYB engine without start/stop. Mine has an ECU from the Beetle 5C; 03L 906 023 KE = CAYC with start/stop system.

--> https://www.volkswagen.nl/over-volkswag ... ner-rijden
- DSG -> check
- Start/Stop system --> check
- TDI engine --> check
- Recuperative braking system --> check (+ energy management via LIN battery sensor and LIN generator)

Of course my car is missing some of the details that make it a true bluemotion model, like the aerodynamic radiator grille, special rims etc.
It does have the 6C Bluemotion rear window spoiler combination though

[ciclo]

Thank you very much, perhaps this is a good time to confess that I am actually a Hamilton fan

Hahaha ...
Super Lewis has been in my Olympus of the gods for a long time, although I currently enjoy all F1 drivers, they are heroes.

Mercedes' strategy was excellent, a shame about that extra second in his first "unexpected" pit stop for Lewis and the subsequent traffic he had to manage, ... I guess it is the risky bet of the great champions.
And still Lewis was able to do an excellent GP, ... underline that Lewis has been impeccable throughout the grand prix, he is a champion!!

Super Max and RB have been outstanding, as it should be to achieve a well-deserved Victory, on a beautiful circuit with very nice orange Fans/Crowd.

A super exciting Dutch Grand Prix!!!

[iichel]

It was indeed a great race and a deserved winner, and it kept me excited for the full race. Not something that happens a lot.
And this week we go to Italia
And I had some very exciting days with all the announcements for Kimi, Gasly, Yuki, Bottas, Russell, Albon and Latifi. What's more to come?

----

How to adapt the turbocharger with a vacuum pump: give it -650mbar of pressure, voltage should be 0.760V.

[iichel]

I mod I did a long time ago, but have not written about yet.

Polo 6R GTI air intake CAVE / CTHE 6R0129618D + 6R0129621B

September 1st 2017, four years ago







http://www.oemepc.com/vw/part_single/ca ... g/e#sec_10

[mirceaculita]

Did you notice any difference after the upgrade?

[iichel]

Makes more 'whooosh' sounds upon rapid acceleration and deceleration. No extra power.

[mirceaculita]

Whoosh sound best sound imo

[ag69]

Makes more 'whooosh' sounds upon rapid acceleration and deceleration. No extra power.

Good one!!!

[ciclo]

Makes more 'whooosh' sounds upon rapid acceleration and deceleration. No extra power.

... is that a non-codable Soundaktor?

[ciclo]

It was indeed a great race and a deserved winner, and it kept me excited for the full race. Not something that happens a lot.
And this week we go to Italia
And I had some very exciting days with all the announcements for Kimi, Gasly, Yuki, Bottas, Russell, Albon and Latifi. What's more to come?

What the hell did they do? https://imgur.com/9SJ8yXt