TDI FAQ - Dump Valves, Part Nos and much more info - Start Here

Discussion in 'TDi - SEAT Diesel specific topics' started by sssstew, Oct 21, 2009.

  1. sssstew

    sssstew Editing your spelling

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    Please note this is a merge from the old TDI FAQ, some links might be missing the old pics for example and some info might need updating. This thread can continue to be updated by adding new posts to it. Note that a general search of the TDI section can yield new results on old topics so for the latest information this searching is recommended.

    Use these as guides. We make no guarantees as to the accuracy of this information, so use at your own risk. The owners and administrators of SEATCUPRA.NET will not be liable for any damage incurred after trying something stupid, and completely destroying you TDI.

    New to diesel
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=29712

    Discussion and a very conclusive method for running in your TDI from an experienced TDI club member :-
    http://www.seatcupra.net/forums/showthread.php?p=540546#post540546

    VAG TDI OIL APPROVALS
    505.00 - Diesel, SDI, TDI (90hp &110hp)
    505.01 - PD TDI engines (115hp,130hp,150hp,75hp 1.4tdi, 2.5l (150,163 & 180hp), 3.3l, and the all new 4.0l)
    506.01 - Diesels with variable service

    MAF information:
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=27511
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=27782
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=26209
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=23771
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=28247 (Mercedes Pierburg MAF thread)

    Info on Modified turbos :
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=24149

    Tuning Box info:
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=26686
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=25694
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=24729
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=28015
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=25178
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=22275

    How to get more fuel in your tank ("venting"):
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=24355

    Running in a TDI
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=22790

    EGR
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=27813
    EGR mod problems with MY 04 TDI's :-
    http://forums.tdiclub.com/showthread.php?p=663554
    Further TDI EGR info here:
    http://www.seatcupra.net/forums/showthread.php?t=38535

    CAT Removal & Exhaust info:
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=27364
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=26859
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=24652
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=23223
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=23088
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=20756
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=14144

    VNT & Non-VNT turbo info:
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=24571
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=23074
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=17645
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=17520
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=14514
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=5159
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=23766
    http://www.seatcupra.net/forums/showthread.php?s=&postid=293491#post293491

    Difference between 130tdi and 150tdi turbo:
    http://www.seatcupra.net/forums/showthread.php?t=39523

    Discussion on turbo boost:
    http://www.seatcupra.net/forums/showthread.php?t=36341

    Paulos information on when changing from a 130 turbo to a 150 turbo :-
    http://www.seatcupra.net/forums/showthread.php?t=46355

    A very very simplified diagram and explanations of how a turbocharger works
    http://auto.howstuffworks.com/turbo.htm

    MPG threads:
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=24404
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=24360
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=25900
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=20085

    Badges:
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=27235
    More rear badge stuff:
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=28858

    Injector Swaps:
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=28188
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=7847
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=8312
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=10001

    See this rather techy post for more in depth details of the PD pumps/injectors
    http://www.seatcupra.net/forums/showthread.php?t=54968

    Down on power
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=28031

    TD tuning box for 110 owners

    http://www.seatcupra.net/forums/showthread.php?s=&threadid=28603

    _____________________
    Brief 110 Tuning box Q&A

    What sort of box would I need?
    Either a 8 or 10 pin tuning box, dependant on age of car, but generally any 2000 onwards cars are 10 pins on the connector to the fuel pump. Can be found under the engine cover, behind the dipstick. Generally any tuning box for the old 90 or 110 engine is suitable, but two people I know have a www.tdperformance.co.uk one with good results.

    Where do i get one from?
    From the web site above if u want one of them, but there are loads now available on ebay, where they can be bought for as cheap as £99

    How easy are they to fit?
    Simple, just remove engine cover, unplug socket as above pug in the box, put engine cover back on.

    When fitted, what would bhp, torque and performance figures go up to? For your 110, you can expect another 30bhp and 30lb ft of torque. You can expect to knock a second or two off your performance figures.
    ___________________

    TDI 110 and injectors
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=28188

    CCV bypass thread
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=28716
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=33405

    Intercooler information:
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=29019
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=22449
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=21155
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=17252
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=13861
    (wheel arch venting for IC)
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=24237
    (IC design)
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=27243
    Intercooler problems:
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=37184

    SPT & other improved breathing (intake info):
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=21110
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=24028
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=23223
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=15921
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=23083
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=27977
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=24908

    Air Filter information:
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=25397
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=19218

    Engine coolant sensor part no for Leon / Toledo
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=29427

    Leon / Toledo Part number for expansion bottle :-
    1j0121403b (VW Dealership supplied)
    This covers the on Start-up (Cold) Engine Temp Bleep Flash Light... Which can be over come quickly by just simply switching off & back on again, or Change the expansion bottle / Sensor top right fails but it is incorporated within the bottle..

    Merc MAF Fitting and results
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=29581
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=30115

    TDI clutch bearing problems:
    http://www.seatcupra.net/forums/showthread.php?t=36212

    __________________

    See the link below for a technical PDF on the workings of the VAG TDI engine, it’s the 90/110 version shown but most of the principles are the same for the PD just the injection system will differ. A very, very useful official VAG document.

    http://www.seatcupra.net/files/tdi-tech.pdf
    __________________

    Thread about standard Ibiza 130 air filter & part number:
    http://www.seatcupra.net/forums/showthread.php?s=&threadid=28776

    160PD Ibiza Cupra intake for the Ibiza 130PD (from Muddyboots)

    6LL 129 621 - bumper end connecting bit
    6LL 129 618 - main pipe from airbox

    Installation:
    Quote:
    Referring to the parts as:
    Front inlet -> Adaptor -> Pipe -> Airbox
    ...where the Adaptor & Pipe are the bits being changed, this is how I did it:

    1) Remove cross-head screw from airbox, pull old pipe out of airbox so the end is free
    2) Remove 2 torx screws from front inlet, lift whole assembly out.
    3) Prise front inlet off of old adaptor & hose. Chuck the old adaptor & hose.
    4) Fit new hose into airbox and refit the crosshead screw
    5) Clip new adaptor into front inlet
    6) Refit front inlet & new adaptor using 2 torx screws (whilst pushing new pipe down out of way)
    7) Bend the new pipe over the new adaptor and push together, pretty fiddly, requires a fair bit of bending of the pipe (which is quite flexible).

    Some interesting maintenance videos by the tdiclub.com guys can be found here
    http://pics2.tdiclub.com/video/cincitdi/index.html

    PD 100,115,130,150 and 160 engine internal part number differences:
    http://www.seatcupra.net/forums/showthread.php?t=68606

    2.0 TDI 140 and 170bhp differences (cheers to stocky) :-
    http://www.seatcupra.net/forums/showthread.php?t=93280

    Silicon Dielectric Grease - Smoother running, more responsive & less smokey TDI!!
    http://www.seatcupra.net/forums/showthread.php?t=101577

    Diesel dump valve information
    http://www.seatcupra.net/forums/showthread.php?t=235874

    DPF Emergency regeneration
    http://www.seatcupra.net/forums/showthread.php?t=131536

    110 vacuum system and other diagrams
    http://www.seatcupra.net/forums/showthread.php?t=207787
     
  2. sssstew

    sssstew Editing your spelling

    Joined:
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