2012 jetta tdi mods

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About Kerma TDI

Welcome to Kermatdi! KermaTDI is the combined effort of a group of really bright and enthusiastic people who are passionate about the turbo diesel market.

Headquartered in Colorado, we first made our name by introducing nozzle upgrades to the diesel world in 2002 more than a decade ago and focused our resources on Turbo Diesel Innovation. By so doing, we started an entirely new automotive performance niche. The existence of more powerful fuel injectors drives the need for supporting components, such as turbos, camshafts, and clutch upgrades, and of course ECU tuning to tie it all together. After over a decade of supporting the turbo diesel community we remain the premier vw/audi diesel performance part provider, and a primary innovation center, driving many aspects of diesel performance trends worldwide.

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Sours: https://kermatdi.com/

Volkswagen 1.9L/2.0L TDI

Between 1997-2015 Volkswagen introduced a series of turbocharged 4-cylinder diesel engines into their lineup of passenger cars available in the USA. These new engines received the TDI (Turbocharged Direct Injection) designation and were offered in the Jetta, Golf, Passat, and Beetle. The addition of a diesel engine provided superior fuel economy and overall better performance over the gasoline options. The TDI engines were constructed with many similar features that were found in diesel engines in heavy-duty applications for enhanced durability.

1.9L TDI

In 1997 the 1.9L diesel was introduced as the first generation TDI engine. This inline 4-cylinder engine had a durable foundation of a cast-iron block with a cast-aluminum head. The 1.9L TDI featured a belt-driven single overhead camshaft (SOHC) valvetrain with 2 valves per cylinder. Within this engine were cast-aluminum pistons with forged steel connecting rods to withstand the high cylinder pressure of a diesel. Volkswagen utilized a Pumpe Duse (PD) direct injection (also known as a unit injector) fuel system on this generation of TDI engines. This fuel system utilized a Bosch VP37 electronic injection pump and mechanical 5-hole nozzle fuel injectors. Mounted to the 1.9L TDI was a vacuum-actuated Garrett VNT-15 variable-geometry turbocharger (VGT). To meet EPA vehicle emission regulations an exhaust gas recirculation (EGR) system was included on this engine. A stock 1.9L TDI was rated at 90 hp and 155 lb-ft of torque. The 1.9L TDI was discontinued after the 2003 model year and was replaced by an all-new turbocharged diesel engine.



In 2003 the inline 4-cylinder 2.0L TDI PD was introduced in Volkswagen passenger cars. This engine shared many components with the 1.9L that continued to provide reliability and performance. The durable foundation of a cast-iron block with a cast-aluminum head was carried over but the cylinder head was redesigned for the 2.0L TDI. The cylinder head was remodeled with 16 valves and double overhead camshafts (DOHC) valvetrain driven by a timing belt. The internals of the 2.0L TDI PD were cast-aluminum pistons with forged steel connecting rods that were designed to handle increased cylinder pressure. This generation of the TDI engine continued to employ a Pumpe Duse (PD) direct injection or unit injector fuel system, hence why this engine was commonly referred to as the 2.0L TDI PD. A vacuum-actuated Garrett VNT-15 variable-geometry turbocharger (VGT) was also fitted to this engine. Volkswagen continued to utilize an exhaust gas recirculation (EGR) system on their diesel engines. The power output of the 2.0L TDI PD ranged from 140-170 hp and 236-258 lb-ft depending on the vehicle’s engine code.



The second generation of the 2.0L TDI was introduced in 2007 and included multiple new enhancements for improved power and efficiency. The cast-iron block with an aluminum 16 valve cylinder head continued to be the durable foundation of the 2.0L TDI. Cast-aluminum pistons and forged steel connecting rods were carried over from the 1.9L engine. The compression ratio was lowered to 16.5:1. The most important upgrade to the 2.0L TDI was converting to a high-pressure common rail fuel system. This generation of the TDI would be referred to as a 2.0L TDI CR to separate it from the previous engine. Switching to a common-rail fuel system helped decrease fuel consumption, engine noise, and emissions. The Bosch injection pump and piezo-electric fuel injectors also delivered better atomization and helped increase the power output of the 2.0L TDI CR. Another upgrade to this engine was a new electronically controlled Garrett variable-geometry turbocharger to increase performance. As emission regulations increased VW added a diesel particulate filter (DPF) system along with the EGR system to significantly reduce emissions and reduce soot exiting from the tailpipe. With all the new improvements a stock 2.0L TDI CR was rated at 170 hp and 350 ft-lb of torque. Production of this engine was halted in 2015, but it is still supported by many aftermarket manufacturers.

XDP continuously works with these aftermarket manufacturers to provide parts and accessories for all types of diesel applications. Shop hundreds of the top manufacturers to find everything your Volkswagen TDI needs. Find custom parts and accessories to give your car a one-of-a-kind appearance. Maintain your vehicle’s factory performance with the stock replacement components available at XDP. XDP has everything needed to get the most out of your Volkswagen 1.9L/2.0L TDI.

Sours: https://www.xtremediesel.com/mm5/
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VW TDI’s are the cars that put the diesel’s “smokey, smelly, sluggish” reputation to rest. Volkswagen TDI’s are the ultimate economy car, with many averaging 40 to 50 mpg. If you want to keep the economy but add some zip to your TDI, we can help you choose the right upgrades for your car. Options include adding a cold air intake kit, a TDI performance chip or power module, injectors or nozzles, upgrading the exhaust or turbo, or making one of many other TDI performance parts your own. Parleys Diesel Performance offers the TDI Performance mods you need to get even better diesel fuel mileage, and to awaken the power of the sleeping beast in your TDI engine. We offer TDI upgrades from some of the best brands in the business. To see parts specifically for your VW TDI, choose your year and engine displacement.

AFE Air Intake Installation Video for 2009-2015 VW TDI

2015 VW 2.0L TDI Performance Upgrades

  • 2.0L VW TDI Performance Modules
  • 2.0L VW TDI Cold Air Intake Systems
  • 2.0L VW TDI Water-Methanol Injection Kits

2009-2014 VW 2.0L TDI Performance Upgrades

  • 2.0L VW TDI Performance Modules
  • 2.0L VW TDICAT-Back Exhaust Systems
  • 2.0L VW TDI Cold Air Intake Systems
  • 2.0L VW TDI Water-Methanol Injection Kits
  • 2.0L VW TDI Gauges & Digital Monitors

2009-2014 VW 3.0L TDI Performance Upgrades

  • 3.0L VW TDI Performance Modules
  • 3.0L VW TDI Premium Replacement Air Filters
  • 3.0L VW TDI Performance Mufflers
  • 3.0L VW TDI Water-Methanol Injection Kits
  • 3.0L VW TDI Gauges & Digital Monitors

2004-2006 VW 1.9L TDI Performance Upgrades

  • 1.9L VW TDI Performance Modules & Tuners
  • 1.9L VW TDI Exhaust Systems
  • 1.9L VW TDI Camshafts
  • 1.9L VW TDI Injectors
  • 1.9L VW TDI Performance & Replacement Turbos
  • 1.9L VW TDI Cold Air Intake Kits
  • 1.9L VW TDI Premium Replacement Air Filters
  • 1.9L VW TDI Performance Mufflers
  • 1.9L VW TDI Water-Methanol Injection Kits
  • 1.9L VW TDI Gauges & Digital Monitors

1999-2003 VW 1.9L TDI Performance Upgrades

  • 1.9L VW TDI Performance Modules & Tuners
  • 1.9L VW TDI Exhaust Systems
  • 1.9L VW TDI Camshafts
  • 1.9L VW TDI Injectors & Injector Nozzles
  • 1.9L VW TDI Performance & Replacement Turbos
  • 1.9L VW TDI Cold Air Intake Kits
  • 1.9L VW TDI Premium Replacement Air Filters
  • 1.9L VW TDI Performance Mufflers
  • 1.9L VW TDI Water-Methanol Injection Kits
  • 1.9L VW TDI Gauges & Digital Monitors

1996-1998 VW 1.9L TDI Performance Upgrades

  • 1.9L VW TDI Performance Modules
  • 1.9L VW TDI Exhaust Systems
  • 1.9L VW TDI Camshafts
  • 1.9L VW TDI Injectors & Injector Nozzles
  • 1.9L VW TDI Premium Replacement Air Filters
  • 1.9L VW TDI Performance Mufflers
  • 1.9L VW TDI Water-Methanol Injection Kits
  • 1.9L VW TDI Gauges

Not sure what kind of TDI performance parts you need? Here at Parley’s Diesel Performance we want you to be as educated as possible about all your options before you make any changes to your stock TDI. Even if you have already made some changes we want you to know what the next best step is to increase your TDI performance. We have done extensive research and stock only the best parts in the TDI performance market to ensure that you will get the power and increases in fuel economy that you’re looking for. There are a number of TDI performance modifications that you can make to your TDI, with each TDI performance modification serving a different purpose. Let’s break down the main categories for you so you can decide which TDI performance mods will be most beneficial for your particular situation.

TDI Performance Chips or Modules – Although there are many different manufacturers to choose from when it comes to TDI performance tuning modules, we recommend only a few high-quality brands like Diesel Power and Bully Dog. VW TDI power mdules are quite popular for a number of reasons, the biggest one of all being the simplicity of installation. Most TDI performance tuners work the same but they increase TDI performance by doing anything from a simple passive electrical circuit to more complex microprocessor controlled devices. The TDI power modules we sell intercept the signals that go between your ECU and the engine, altering the values as they are transmitted. TDI performance tuning boxes, regardless of exactly how they work, increase your horsepower by safely increasing the amount of fuel delivered at full load; many of them also make changes to the injection timing and duration.

Your fuel injector is the part of your engine that actually injects the diesel fuel into the engine. The tip of the injector is called a nozzle. The nozzle sprays a mist of diesel fuel into the cylinder at which point the fuel combusts. So how will upgrading your VW TDI injectors or injector nozzles increase your TDI performance? Since your injector controls the amount of fuel going into the cylinder, if you upgrade to what are known as “high flow” TDI performance injectors you will then be pouring more fuel into the cylinder, and more fuel properly burned equals more power. How much power? The answer, of course, depends on the size of the openings in the nozzles as well as the amount of air available, but the most popular TDI injector nozzles will add anywhere from 20 to 30 horsepower and a 15% to 20% increase in torque. For truly effective increases in diesel power, you’ll want to add more air along with the fuel. You’ll be fine upgrading to the .205 size injector nozzles with your stock turbo, for example; however, if you wanted the larger 30 horsepower .216 injector nozzles, you would need to upgrade your turbo as well. If you don’t, your TDI will just pour the unburned fuel out the tailpipe as black smoke. TDI performance injector nozzles are a very popular upgrade for 1997-2003 1.9L VW TDI’s.

TDI Performance Intakes – Delving further into TDI performance and the mechanics of diesel engines in general, diesel engines work by combustion. In order for combustion to take place in a diesel engine, air is forced into the cylinder and it is actually the heat of the air that ignites the diesel fuel. So how do “performance intakes” or “cold air intakes” add more power to your TDI? They give you more cold air, and cold air takes up less space than hot air. The more cold air you can get into the cylinder the better because that makes for a more efficient combustion event, translating to more power to the pavement, and the greater the overall increase in TDI performance.

AFE Cold Air Intake Installation Video for 2000-2004.5 VW Jetta & Golf 1.9L TDI

Why make changes to your TDI exhaust system? The main goal with upgrading your exhaust is the reduction of back pressure. This allows the engine to flow more air and improve turbo response, both of which enhance your TDI performance and extend your engine life due to less heat. Although there are some full TDI performance exhaust systems, a full TDI performance exhaust system isn’t always the best way to get the most bang for your buck. To increase TDI performance and air flow what we frequently recommend is installing an Aero Exhaust Turbine Muffler. The Aero Turbine’s design allows it to create something similar in concept to a Venturi type effect. The Aero muffler even flows better than a straight-piped exhaust, in effect sucking the exhaust away from the engine. The benefits include increased horsepower, extended engine life and improved fuel mileage. Just make sure that the Aero Muffler you order will fit your particular TDI Exhaust system, and understand that sometimes some extra fabrication is necessary. Take the measurements of the Aero Muffler you’re looking at to your local muffler shop before buying to make sure they can install it for you.

Sours: https://www.parleysdieselperformance.com/t/vehicles/volkswagen-tdi

Twice the Power, 51mpg: VW Jetta Diesel Mods

Known for their efficiency, simplicity and durability, the Volkswagen Jetta TDI’s produced from ’99-’03 (part of the MK4, fourth-generation cars built from ’99-‘06) are arguably the most fuel-efficient, diesel-powered sedans the German automaker ever produced. Known for its mechanical simplicity, the ALH 1.9L four-cylinder oil burner features a 2-valve cylinder head, a Bosch rotary injection pump that feeds conventional, pop-off style injectors and a vacuum-actuated variable geometry turbocharger. Adding to the ALH Jetta TDI’s tremendous fuel-sipping capability is the fact that it weighs less than 3,000 pounds. However, with just 90 hp and 155 lb-ft of torque available at the crank, these cars feel anything but light on their feet.

What to do? Luckily, a vibrant aftermarket exists for TDI’s. In fact, over the past 15-20 years of playing with these cars, so many parts combinations have been tested that—for all intents and purposes—ALH Jetta performance has been nailed down to a science. From high-flow injector nozzles to drop-in turbo upgrades and performance camshafts to custom tuning, everything is available for them. As icing on the cake, if you can manage to limit the travel of your right foot, these power adders won’t even cause a drop in fuel economy. Below, we’ll explore some of the most proven aftermarket parts available for these loveable little TDI’s.

Plug-and-Play, 30HP Gains

The quickest, easiest way to wake up the ALH 1.9L TDI diesel in ’99-’03 Jettas is to reprogram the ECU. Big names in the tuning game for these cars are Kerma TDI, Malone Tuning, Rocket Chip Performance and TD Tuning. The general consensus on gains with the stock injectors and turbo still in the mix is 25 to 30 hp, but in our own chassis dyno experience we’ve seen a 33hp gain using Kerma TDI’s tuning, made possible via the company’s Q-Loader programmer.

5-Star Tuning

Malone Tuning is highly respected in the tuning realm, with solid power gains accompanied by great drivability (low smoke, linear throttle, etc.) and what is said to be the best customer support in the business. In addition to waking up Jetta TDI’s, Malone offers optional calibrations that can bump up the factory engine idle to reduce vibrations associated with stiff aftermarket motor mounts (a common upgrade), a file that increases glow plug duration for easier winter start ups and a launch control tune for when automatic transmission cars visit the track.

Milder Injector Upgrades

By far, the combination of adding larger nozzles with a corresponding ECU tweak is hands down the biggest bang-for-your-buck pair of mods in the ALH Jetta world. A good entry-level nozzle upgrade offered by Kerma TDI is the Bosio DLC 520, which offers a cleaner burn, a 15-20 hp gain, and can even increase fuel efficiency. A more moderate nozzle upgrade (also from Kerma TDI) is the DLC 1019 nozzle, which can yield as much as 60 additional horsepower (at the wheels) and 110 lb-ft over stock with the factory turbo still feeding the engine.

Going Even Bigger

For folks looking to push their TDI into 200whp territory, Kerma TDI offers a complete power package that includes its DLC Race 520 nozzles, VNT-17 Plus turbocharger, 3 bar MAP sensor (more on that below), ARP head studs and a Colt Cams Stage 2 camshaft with lifters. To keep EGT cool and the clutch from slipping, Kerma TDI also throws in a side-mounted intercooler and a Stage 3 Endurance clutch kit from South Bend. A second injector nozzle option, the popular PP764 nozzle, also offers a path to 180whp or more.

Euro-spec Turbo

Found on the 150hp European version of the 1.9L engine, the Garrett VNT-17 has long been a popular turbo upgrade for state-side Jetta TDI’s. Not only does it provide a path to more power, but it’s been vetted time and again and shown to be one of the most reliable turbochargers in the Jetta segment—even more reliable than the factory VNT-15 while making more boost. It can support more than 160whp with the right injector nozzle upgrade in the mix. Another common option is a hybrid of the VNT-17 known as the 17/22, which is a VNT-17 fitted with the larger compressor from a VNT-20 and that can handle 190whp with a good combination of nozzles and tuning.

The BorgWarner BV39

This little gem has been around for more than six years now. It’s the BV39B from BorgWarner (coined the S7 by Kerma TDI), can support up to 180whp and in excess of 330 lb-ft. The BV39B sports a billet compressor wheel with a 34.5mm inducer (vs. 33mm on the stock VNT-15) and spools approximately 300 rpm sooner than the aforementioned VNT-17. In conjunction with DLC 1019 nozzles and custom tuning, we’ve seen the BV39B support twice the factory torque rating and a 75-percent increase in horsepower without sacrificing any drivability, fuel economy or engine longevity (the car is still running the exact same, six years after the build).

Raising the [MAP Sensor] Bar

Any time you upgrade the turbo on a ’99-’03 Jetta TDI, a higher pressure MAP sensor is a good idea to get maximum performance out of it. When retaining the factory overboost protection functionality, the OEM 2.5-bar MAP sensor will only allow you to make 16-18 psi of boost. With the 3-bar MAP sensor in the mix, roughly 23 psi of boost can be seen. Beyond that, Malone Tuning offers a Bosch 4-bar MAP sensor for even higher boost potential. It’s recommended that a specific ECU tune be written when upgrading MAP sensors, not only to optimize power but also to keep your turbo safe.

11mm Injection Pump

While it can be cost-prohibitive for those on tighter performance budgets, the 11mm injection pumps used on automatic transmission cars makes for a great little factory upgrade for manual transmission Jetta owners. For reference, the factory Bosch pump on manual transmission Jettas is a 10mm version. In addition to the increased volume its 11mm head provides over the 10mm head, the 11mm pump produces a peak injection pressure of 19,000 psi vs. 16,500 psi on the 10mm unit. This means better atomization, which in theory equates to more power, in addition to a cleaner, more complete in-cylinder burn.

Holding Power: South Bend Clutch

With the 02J five-speed manual being a much more reliable option than the four-speed 01M automatic offered in the ’99-’03 Jetta TDI’s, most enthusiasts row their own gears. However, as soon as the first nozzle upgrade is performed the OEM clutch can begin to slip. To harness any amount of power the 1.9L engine can turn out, South Bend offers seven different clutch upgrades. The company builds a Stage 2 Daily that can handle up to 325 lb-ft of torque, a Stage 2 Endurance that’s good for 350 lb-ft and a Stage 2 Drag unit rated for 390 lb-ft. South Bend’s Stage 3 line features a Daily that can hold 400 lb-ft, an Endurance rated for 425 lb-ft and a Drag version capable of harnessing 510 lb-ft. For all-out racing, its Stage 4 Extreme clutch is rated for more than 525 lb-ft. All South Bend clutches come with its 22.5-pound single mass flywheel and new crank bolts.

Colt Cams

Both drop-in replacement camshafts and custom, race-ready versions are available from Colt Cams. The company’s Stage 2 cam, as tested by Malone Tuning, provided a 100-degree F reduction in EGT (exhaust gas temperature) at highway cruising speed, which is fairly impressive. Malone also reported that it took longer to reach their 1,500-degree peak EGT threshold during instances of prolonged acceleration. For cars with larger turbochargers and big injectors, Colt Cam’s Stage 3 cam helps maximize high rpm power and is also a drop-in unit, although it does require some massaging of the lifter bowl in the cam’s nose area.

Is the ALH’s Mileage Really Unaffected by Mods?

Our high mark so far with our own ’03 Jetta TDI has been 51.6 mpg. It’s graced with a set of balanced Stage 1 injectors from Kerma TDI fitted with Bosio DLC 520 nozzles, Kerma TDI’s custom ECU calibration to match the injectors and South Bend Clutch’s Stage 2 Daily clutch. The VW might only make 120 hp at the front wheels (up from 72hp stock!), but the 250 lb-ft of torque that’s on tap at low rpm makes passing cars in fifth gear positively effortless. Despite these mods, the car gets the same 49-mpg average it did when we picked it up in bone-stock form four years ago.

Still Alive in a Post-Dieselgate World

Although Dieselgate did a number on TDI enthusiasm, the ALH-powered Jettas (which weren’t implemented in the colossal emissions scandal) still enjoy a loyal following. In fact, up until a couple years ago the annual TDI Fest would draw dozens of customized versions out of the woodwork. Regardless of whether or not there is a resurgence in diesel-centric VW car shows, the reliable, simplistic and fuel-efficient ’99-’03 Jettas will continue to be sought after by commuters, enthusiasts and collectors alike.

Need a real life example of turning up the wick on an ALH TDI? Check out the 120whp recipe we treated our own ’03 Jetta to right here.

Sours: https://www.drivingline.com/articles/twice-the-power-51mpg-vw-jetta-diesel-mods/

Tdi mods jetta 2012

Q-PRO+ TDI Tuning for 2009-2014 Jetta, Golf, Beetle, Sportwagen (+34whp & +95lb-ft)

The Q PRO+ is the gateway to your custom tune and a higher performing diesel engine.

The QPRO+ offers handheld convenience with a full color touch screen to make flash tuning your vehicle simple and painless. The QPRO+ offers you the ability to switch between the factory tune and a KermaTDI tune within minutes and will produce 22% more peak power and a gain of 34% in peak torque (+34whp & +95lb-ft). These tunes deliver a more consistent power and torque curve, creating a wider and more predictable power band for the driver. The consistency in the power band also minimizes additional stress on the vehicle's engine, clutch, transmission, axles, and driveline mounts. In addition to increased power, KermaTDI customers have seen fuel economy increases up to 10%.

The combination of the QPRO+ and the ability to retain all factory emissions equipment without the need for expensive bolt-on modifications make KermaTDI tunes the best in the market.

Need a little more power? Check it.

Get a great deal on gauges when combined with our tuning. Both PolarFIS and P3Cars offer Digital Paramater Displays that give you real time info on your cars diagnostics. Polar FIS can be purchased for $200 with the tuning here. The P3 gauge can be ordered HERE. Use discount code "P3tuningcombo" to get $100 off the gauge purchase.

(PolarFIS does not work on 2011-2014 Jetta Sedans.)

Key Features of this TUNE:

  • Quicker turbo response (turbo lag is significantly reduced)
  • Consistent power band (no jumps, spikes, or reduced power on hard throttle)
  • Power is very noticeable (feels like you have a new car)
  • MPGs can increase up to 10% (tested on long distance driving)
  • EGT levels are consistent
  • Soot levels are clean
  • Regens not nearly as noticeable
  • Passive regens perform correctly
  • Tuning and support is all done in-house
  • Dyno-proven (Stock dyno pull and tuned dyno for a correct reading of +WHP and +WTQ)
  • Easily the most refined and powerful tune on the market guaranteed!

All emission systems are kept intact and must remain installed. Exhaust flow is not an issue (Europe has 2.0 liter TDIs with 240hp stock from the factory for example). The labor is also very expensive (typically 8hr billable time from a shop plus parts), so we suggest saving your money and spend it on something that helps your build (i.e. suspension, brakes, upgraded turbo, etc.). We also have replacement DPFs in stock if needed.

Please note: The QPRO+ only works on Windows operating systems. Unfortunately, it does not work with Mac OS. 

QPRO+ Install video:

Sours: https://kermatdi.com/i-1103-q-pro-tdi-tuning-for-2009-2014-jetta-golf-beetle-sportwagen-34whp-95lb-ft.html
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