We had the pleasure of providing a custom ECU and TCU tuning service to Michael (THANAS EGYPT) for his fully-built EA888 Mk5 Jetta 2.0 TSI DSG. Specs as follows:
Model: 2010 VW Jetta MK5 2.0 TSI
Engine: 2.0 4-Cylinder TSI EA888 (Turbo charged, direct injection)
Transmission: 6-Speed DQ250 - DSG
ECU: Bosch MED17.5
Location: THANAS EGYPT, CAIRO
Modifications:
- Engine CCZB 2.0 TSI fully forged:
- Ferrera valves and springs
- Mahle pistons
- Bar-tek rods
- Acl race bearings
- IE manifold
- IE cold air intake
- VF Engineering Tubular Manifold
- GTX2871R Turbo
- Autotech HPFP - EA888
- AEM WMI
- Aquamist 4 WMI injectors (Current 1x Boost Pipe Mounted)
- CTS oil catch can
- GFB diverter valve
- Driver mod
The motor was forged and assembled by Michael to perfection. We started out by logging the ECU on it's existing ECU and TCU tunes. The detailed datalogs were used to inform the ECU and TCU tuning process.
Similar to South African conditions, the fuel quality is poor, and the conditions are hot and unforgiving to high boost applications, we took a calculated approach to ensuring that the combustion/in-cylinder conditions were controlled, and made full use of the cooling and knock suppressive effect of DI/TSI tech as well as the WMI kit installed. We quickly discovered that at higher boost levels, the rail pressure was not meeting the necessary request for the power, and the stock HPFP was upgraded with Autotech internals.
We went through a number of revisions, aligning the ECU torque model with the TCU/DSG torque handling to achieve adequate clutch pressure for the torque the motor was now producing. The below videos highlight the importance of correct TCU software.
Before (Existing DSG Tune): Making less power with the older ECU tune and experiencing significant clutch slip with the existing TCU tune as well.
After THANAS/STG3 ECU + DSG Tune: Making substantially more power and with appropriate clamping load on the clutches, with quicker, smoother shifts.
With the DSG tune corrected, it was time to finish dialing in the ECU tune, and the boost could be raised to 1.9 bar safely. More than enough for the GTX2870, and with the owner's future plans in mind, we decided to stop there. A G-series turbo is on order, and we'll continue the tuning when it arrives!
No dyno figures yet, however based on the airflow and advance, it's estimated at around 330 kW and 595 Nm+.
Jetta vs Mk7R
Bonus Long-Golf pics:
Thanks for reading!