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Old 11-05-2007, 12:37   #1
erminio
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Seat Leon FR II TDI tuning...

Next week i will get my new Seat Leon FR II TDI (170bhp) car.
My current car has several mods, i will also mod the diesel car as well.

My plan is to remove the exhaust filter (DRF it is called) and replace it with a Milltek downpipe (directly on the turbo) and a full Milltek exhaust.

After this customizing the ECU for maximum performance

My questions to the diesel wizzkids over here : are there any more mods possible on de FR diesel which assure some gains in power (torque is already enough)
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Old 12-05-2007, 19:05   #2
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Quote:
Originally Posted by erminio View Post
Next week i will get my new Seat Leon FR II TDI (170bhp) car.
My current car has several mods, i will also mod the diesel car as well.

My plan is to remove the exhaust filter (DRF it is called) and replace it with a Milltek downpipe (directly on the turbo) and a full Milltek exhaust.

After this customizing the ECU for maximum performance

My questions to the diesel wizzkids over here : are there any more mods possible on de FR diesel which assure some gains in power (torque is already enough)
Don't think you can ditch the DPF.

1) The ECU is linked into it somehow, meaning loosing the DPF and the ECU throws a wobbly.
2) The MOT's nowadays know what your emissions should be, in 3 years time, if they are a certain % over what they should be it becomes a fail.

Couple of tuners have managed to get around 200bhp out of the cars with the DPF, or course, a couple of other tuners have set fire to the DPF and the car while trying ....
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Old 16-05-2007, 11:31   #3
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Removing the DPF will result in less resistance in the flow, thereby it is possible to gain more with a custom chip.

My tuner has already done one without the DPF and the results were promising 229bhp and 440nm (the car was made for racing purpose).

The problem you get when removing the DPF is that it contains 4 sensors which will generate alarms on you display.

My tuner will remove these alarms in the ECU and therefore he needs to work on my car for a week

I will pick-up my car today.., within 4 weeks a will have it run throug its first 2000km and than the Full Milltek exhaust will be ready to install.
Then i bring to the car to my tuner for the ECU change.

I keep you informed about the performance
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Old 16-05-2007, 12:53   #4
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Sounds interesting, keep us all informed.
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Old 17-05-2007, 15:25   #5
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Originally Posted by aceman View Post
Sounds interesting, keep us all informed.
I will post my dyno run (on a proffesional SuperFlow WinDyn bench) up here
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Old 18-05-2007, 21:15   #6
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do milltek do a system for the FR TDi yet? or is it a modified MK5 golf system.
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Old 21-05-2007, 07:47   #7
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Originally Posted by k4ith View Post
do milltek do a system for the FR TDi yet? or is it a modified MK5 golf system.
They told me they are developing at least a new downpipe for the Seat Leon for customurs who want to remove the DRF.

I can imagine if the MK5 golf systems parts fit on the Seat Leon it will be the same
http://www.millteksport.com/news.read.cfm?articleid=77

I have my car now and driving it throug its first km..., my first impression is good, but i lack a bit of power, which will be sorted out soon
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Old 20-06-2007, 10:06   #8
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Standard Chip is in now and definitly more power and torque.
Values for the chip are 200bhp/420nm.

Have ordered a custom exhaust from EPS, 63mm RVS, no DRF and only the end resonater. After a week i will have it fitted and the ECU will be custom made for the EPS exhaust. Also i run on the dyno for the results
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Old 09-07-2007, 12:07   #9
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Here some pictures of the new exhaust, the DPF and the very tight corner in the standard exhaust.

Lower part of the car...


Much to tight corner in the exhaust with DPF...


Comparison old and new...


Tomorrow the car is of to to assemble the new exhaust and the custom software
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Old 09-07-2007, 13:19   #10
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Interesting !

Have the tuners worked out how to prevent the ECU from throwing a fault yet?

I presume the 4 bosses on the old exhaust are where the sensors went.
Any idea what the sensors detect ?

Also - any idea if the downpipe/DRF is the same part as fitted to the Altea PD170 ?

Last edited by muddyboots; 09-07-2007 at 13:23. Reason: Speling
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Old 09-07-2007, 19:56   #11
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I know that the tuner knows how to disable the 4 sensoralarms from the DPF (the 4 bosses you mentioned) and prevent the car to go into alarmmode

Don't know exactly what the 4 sensors detect but i guess heating, airflow, ???

Don't know but a guess if it is the same engine the DPF will also be the same.
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Old 12-07-2007, 07:46   #12
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Originally Posted by erminio View Post
I know that the tuner knows how to disable the 4 sensoralarms from the DPF (the 4 bosses you mentioned) and prevent the car to go into alarmmode

Don't know exactly what the 4 sensors detect but i guess heating, airflow, ???
Just found some clues about what the sensors measure, see here:
http://wiki.ross-tech.com/index.php/...y_Regeneration
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Old 12-07-2007, 08:43   #13
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I think the look like they are the ones were talking about, thanx :-)
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Old 12-07-2007, 11:04   #14
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There's an (advertisement) article in this months (Aug) "What Diesel Car" where they've bunged a new Tunit module onto a Mk II Leon FR 170. Claim it produced a peak of 195 BHP and 291 lbft torque @ 3489 rpm with 285 lbft from 2600 to 3600 rpm.
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Old 12-07-2007, 12:10   #15
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Erminio - any idea when you'll get your car dyno'd ?
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Old 12-07-2007, 12:26   #16
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Originally Posted by muddyboots View Post
Erminio - any idea when you'll get your car dyno'd ?
If everything goes to plan i will pickup my car this Saturdaymorning

The car is already dynoed then or i will let it run on Saturdaymorning .., keep you informed
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Old 14-07-2007, 15:16   #17
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Got my car and its definitly faster as before.., also the sound is amazing, when you drive a constand speed its almost the same as original, but whe you opens the throttle instantly the sound changes to a real racing sound

Specs are 223bhp and 477nm of torque .., i will place the dyno later on
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Old 15-07-2007, 17:27   #18
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That's impressive - so that's just by removing the DPF, changing the exhaust and a remap ?

How is the clutch coping with 477NM ?I can't remember the conversion offhand but that's quite a way over 300lbft isn't it, which is generally considered the maximum the standard clutch can handle.

Look forward to seeing the dyno results.
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Old 15-07-2007, 21:11   #19
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Originally Posted by muddyboots View Post
That's impressive - so that's just by removing the DPF, changing the exhaust and a remap ?

How is the clutch coping with 477NM ?I can't remember the conversion offhand but that's quite a way over 300lbft isn't it, which is generally considered the maximum the standard clutch can handle.

Look forward to seeing the dyno results.

Clutch must able to handle this torque just fine. My tuner had it over 500nm..., but that was to much and came in to aggresive. These 477 are coming in hard but not instantly, i bit more smooth

This afternoon i ran into a BMW 535d touring and we did some sprints on the highway.., first one when he started behind me and i had to shift down to 5 before i could floor it..., (a cloud of black smoke from my exhaust) first he passes me thro his momentum..., but then a was gaining the lost ground quit quickly. At 220km/h i was up his tail

Second time a was behind him (not to close to avoid the slipstream) and from 130km/h untill 230km/h a could follow without any problems

Looking at the specs from both cars ;

BMW 1730kg/272pk = 6,36
Seat 1280kg/223pk = 5,74

Take into account all BMW 535d are automatic..., so i'am starting to get happy with my car
Looking at his face when he let me by i guess he will go to the garage tomorrow morning for a powertest, because he was slower as a 170bhp Seat Leon FR Diesel

Herewith my dynoplot...

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Last edited by erminio; 16-07-2007 at 08:02.
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Old 22-07-2007, 20:45   #20
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Originally Posted by Weisel_T View Post
hi there where did you get the map done
and how much has the tuning parts cost you so far?
I've done the installation of the custom exhaust by JD Engineering (also called the VAG dokter) (http://www.jdengineering.nl/ ) and he also wrote the software.

I have paid EUR 1250,- for the custom made exhaust by EPS (http://www.uitlaten.com/main.html), for the software i have paid the normal price EUR 690,-. The custom made software for the ECU regarding the exhaust, re-writing the sensors and ERG regeneration process cost me not so much, because it was a sort of experiment

He told me that for other TDI's it would be more expensive because of the extra hours it needed to make it custom. The firmware of the cars is changing a lot these days due to the enviroment issues carmakers have to deal with, so re-using my settings is just partly possible.
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