PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo

Started by 80 Vert, March 10, 2010, 06:30:38 PM

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80 Vert

Some new hardware arrived today in the form of a pair of HGP turbo's and manifolds and an HGP/HPA 3.6 turbo inlet manifold with injectors and fuel rail. Next month will see the new gearbox and transfer case arrive, a DQ500 7 speed dsg.
Thought it a waste of time to try and make the DQ250 from the Passat try to cope with what the engine will be capable of delivering so hence gearbox change as well.
Poor car has no idea whats in store  >:D

2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

rambo_005


spooln

77 CS1 Fiat Spider. 78 Mk1 Scirocco. 83 Mk1 GTI. 12 Abarth 595C Competizione. 18 Golf R. 20 Kodiaq vRS

80 Vert

#1303
Factory in RS3, TTRS and a few others. Handles double the torque of the DQ250.
My current train of thought is to swap in full MK5 electronics to make integration easier but that's still a little ways down the track.
Decided best option is to keep stock FSI and run piggy back ecu to run 6 extra injectors and separate fuel supply when on boost.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

RS ZWEI

Thats going to be mad John. Any idea how how much power it will be putting out?
1980 VW Golf GTI Track Car
1995 Audi RS2
2003 Mini Cooper S (Written off - rear ended)
2005 Mini Cooper S
2006 Skoda Octavia vRS Combi
2009 Renault Megane 230 R26 (Written off - rear ended)
2013 Renault Megane RS265 Redbull RB8

80 Vert

Aiming for 650-700 although it should be able to do a lot more
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

spooln

Std bottem end ok or shiny new  bits in there as well?
77 CS1 Fiat Spider. 78 Mk1 Scirocco. 83 Mk1 GTI. 12 Abarth 595C Competizione. 18 Golf R. 20 Kodiaq vRS

80 Vert

2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

GLIDN

Quote from: 80 Vert on June 23, 2016, 09:37:00 PM
Factory in RS3, TTRS and a few others. Handles double the torque of the DQ250.
My current train of thought is to swap in full MK5 electronics to make integration easier but that's still a little ways down the track.
Decided best option is to keep stock FSI and run piggy back ecu to run 6 extra injectors and separate fuel supply when on boost.

Why not tune OEM ECU?
It's more than up to the task to handle your request.
Look at AP's R36TT mk5 R32. He is running north of 700hp and still on OEM management running 10.4 or 10.6 in full street trim last time I checked.
Audi A4 DTM - K04 NZ New | All bolt-ons | Carbon Clean done
2012 MK6R Golf |Stage 3+ | Stage 4 DSG | Tuned & Built by HSP Tuning

80 Vert

I will be running oem ecu, MK5 R32 harness with the Passat ECU
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

Engine strip downs completed, R36 engine with broken block is completely stripped and my donor crispy fire damaged 3.6 engine also stripped.
Going forward I intend to use the forged BWS crank from the R36 along with the head and cams and put that in to the donor 3.6 block.
Have both side by side to compare but so far they both look identical.
One cylinder on the crispy engine has had water in it but scaping the remains away it doesn't look like the bore is damaged, a light hone will reveal if its ok to use.

Ordered head studs and main studs, have IE rods already so that just leaves pistons to sort.
Current thinking is to use the R36 ECU to run FSI as per standard and some sort of piggy back system to control the 6 other injectors in the manifold under boost.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

The damaged R36.......Block and pan are toast. Hopefully the crank isn't bent. Spins free but dial gauge will tell the story once I place it in the good block.

Stripping engine #2, crispy the fire damaged motor.
Upon a light hone in the cylinder that has had water sitting it turns out the bores are quite worn.
Not huge mileage on this but perhaps wrong oil used who knows. Block will need boring.
On the plus side check out the port sizes!! No wonder these things make epic power.


2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

le mans

Hi John, is this an old project you had parked or have you suffered a recent engine failure? Always interesting to see what you?re up to!

80 Vert

I've had this engine for many years Jon, the R32T I had in this car was sold 5 years ago and had always planned to put the R36 in but just never really got there till now.
The broken engine I harvested out of a R36 Passat I wrecked many years ago and has sat ever since.
I'll build this up with forged internals as I've got twin turbos to go on it.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

superfueler

This car will be something to behold when its done. I'll be watching with interest.  :D
Current: 2010 Audi A4 2.7 TDI silver, 2007 Audi A4 2.0T DTM sprint blue, 2007 VW Golf V 2.0 TDI BKD 4motion manual white.
Past: 2004 Golf R32 black pearlescent, 2009 Audi S3 white, 2004 Audi A4 B6 1.8T blue, 99 Golf mk4 GTI black, 2005 Audi A4 B7 2.0T black.


80 Vert

The clutch for this project came in today, all I can say is wow!!
I had not heard of this company until I saw them mentioned in a really interesting youtube video and decided to contact them.
Right from the get go their communication and professionalism was outstanding, anyway I placed an order for their twin plate clutch set up and got their input shaft support kit as well.
Unboxing the clutch today it is very very high end, the quality just looks absolutely superb and a shame to hide away in the bell housing.
This particular set is a 2 plate rated at 1200NM torque which should be good on my twin turbo set up.
If anyone is looking for a serious single or double plate clutch contact TTV Racing UK.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

rambo_005

Does this mean you're no longer going with the DSG?

80 Vert

Absolutely yes, no more DSG. Don't know what I was thinking considering DSG  8)
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration