2.0 TFSi Tuning Info

tfsi engine remap gti

2.0 TFSi Tuning Info 

R-Tech booking and help line 02476 34 94 91

R-Tech Performance  have over 15 years tuning background with close on 10 years dedicated to BOSCH ecu based custom tuning we have evolved with each generation Bosch ecu and engine combination.  Before moving on to the next new engine setup we like to fully learn and understand the current / older setups and to excel to to top of the game before moving on to new grounds. The MED9 Bosch ecu which control the TFSI engines are a built on the same base structure as the ME7 ecu found in the 1.8T engines, the only major difference is  the TFSI run direct injection (GDI) which means the fuel is injected at 110bar into each combustion chamber directly, unlike the 1,8T 20v where the injectors are located in the inlet manifold injecting fuel @3bar on to the back of the inlet valves pre mixing with the air.    The advantage with the tfsi high pressure injection method is better knock suppression and emissions due to combustion chamber design and better fuel atomisation which allows the engines to run higher compression ratios at hotter combustion temps.  The result of higher compression ratio and better knock suppression is the reason the TFSI engine is one of the best tuneable engines in the world,  awesome part throttle light load response which moves quickly into a strong broad torque band which hols well creating amazing area under the power curves.

The TFSI engine was first used in late 2003 in the Audi A3 up until 2012 in the Golf R  Golf 2012.

There are two turbo versions fitted to TFSi engines, version one is the k03 which can be tuned to max of 300hp 350lbft and then version 2 the K04 turbo which has been seen running 400hp 450lbft with supporting hardware.

engine code

 Do You Want More Power From Your Car????  If so then please read below so we try to help and advise you the best we can to make your tuning experience a good one.

The first thing you need to know is your engine code and turbo version.  VW Audi Skoda and Seat all use basically the same hardware with factory power ranging from 180BHP to 270hp.   You will have a sticker on the boot floor of the car under the carpet near the spare wheel well. The sticker shows three letters which states the engine code your car is running (which can be seen in red on the image to the right) 

AXX = K03 turbo  Audi A3 VW Golf 2003-04

BWA = K03 turbo  Audi Seat Skoda VW 2004+

BYD = K04 turbo  VW ED30 & Pirelli edition Golf GTI

BWJ = K04 turbo Seat Leon Cupra, K1 and Cupra R

BHZ = k04 turbo  early Audi S3

CDL = k04 vary HP versions found in the Audi S3, Golf R and Golf ED35

(cams pistons rod injectors also differ between codes)

The TFSi K03 based AXX BWA peformance guide

  • Stage 1 custom remap                                                    230-250 hp        290-310 lbft 
  • Stage 2  custom remap                                                265-275 hp        315-330 lbft
  • Stage 2+ custom remap                                                275-290 hp        355-360 lbft
  • Stage 3 k04 0r k03 hybrid custom remap            330-350 hp        350-370 lbft

Hardware Combination of tuning level options K03 TFSI

  1. Stage 1 =  Any hardware upgrade as long as cats and fuel pump stays oem
  2. Stage 2  = Intercooler – induction kit – sports cat / decat full performance exhaust
  3. Stage 2+= Hpfp – intercooler – induction kit – sports cat / decat full performance exhaust.
  4. Stage 3 = Stage2+ hardware upgrades with K04 or  K03 Hybrid turbo with s3 injectors and RS4 pressure valve.

The TFSi K04 based BYD BWJ BHZ CDL engines can be tuned upto: 

  • Stage 1 custom remap                   290-310 hp        290-320 lbft 
  • Stage 2  custom remap                 315-340hp        320-340 lbft
  • Stage 2+ custom remap                355-380 hp        350-400lbft
  • Stage 3  custom tuning                  400-550hp        400-550 lbft

 Hardware Combination of tuning level options K04 TFSI enignes BYD BWJ BHZ CDL

  1. Stage 1 =  Any hardware upgrade as long as cats stay stock
  2. Stage 2  = Intercooler – induction kit – full performance exhaust
  3. Stage 2+= HPFP – intercooler – induction kit – full performance exhaust – RS4 pressure valve and clutch is you want the best torque
  4. Stage 3 =  hybrid turbo & gtx gt hta htz big turbo setups with upgrade injectors bigger mafs ect. fully bespoke tuning solutions

Before getting your car mapped there are a few things which we want to point out to you so you don’t have major issues or poor performance results. We can supply and fit any of the items below prior to your tuning session. when bookinf please let us know what you needs and we will plan to get you here early so we have time to fit the items you require

  • HPFP CAM FOLLOWER 06D109309R check kist dude
  • DIVERTER VALVE  06F145710G
  • PCV SYSTEM 06F129101R
  • ENGINE OIL 5W 40

1:  The TFSI engine uses a high pressure fuel pump (HPFP) system which runs on the inlet cam via a cam  follower.  The HPFP followers are prone to wearing and causing fuel issues which can lead to engine damage.  We advice to have the fuel pump cam follower changed before mapping and at every major service. The follower only costs around £29 from a main dealer.  The cam follower part number is 06D109309R   The picture below illustrates the wearing process of the HPFP cam follower stage1 follower is the stage of wear where you want to change it before causing damage leave it too late and the follower will end up like the follower show at stage4 the point where metal parts break off and go into the engine, the inlet cam gets damaged and the fuel pump piston get worn down beyond repair,   If you let the cam follower get to stage4 damage then the repair bill could end up close on £2000!!!       So keep on top of the follower and replace it every major service.

NOTE !!!!  You want to catch your follower just BEFORE stage 1 level of wear.  You want to see the follower without any silver showing on the face

Stage 1 should be safe and not damage to the cam.

Stage 2 and 3 you will need and to inspect the cam make sure no damage, there have been cases where the cam is worn and damaged

Stage 4 will need a full strip down new cam and fuel pump, cam cover cleaned and sump cleaned

hpfp cam follower tfsi
d dv and split

1: The early oem diverter valves are prone to splitting a leaking, some upgrade to the D version valves which eliminates the splitting issues but are prone to leaking under extream loads.  We recommend that the G revision valve is used which only costs around £45 from a main dealer.  The DV is to be treated as a consumable part which will wear and fail over time.  The correct part number for the G valve is 06F145710G.

tfsi pcv system

2: The TFSI run a poor design breather system which uses a one-way valve to stop the boost bleeding off, this one way valve is prone to faling and causing the turbo to over speed with the engine loosing power and MPG goes down.

3: As part of the remap service we will check the PCV system free of charge before starting to tune the car so don’t worry too  much about having to replace or checking the DV yourself we will make sure all is ok before tuning.

4: Which engine oil to use in a  2.0 TFSI?

The most commonly recommended oil for the TFSI engine is 5w30.  Under extreme conditions on a stock un-tuned engine the 5w30 oil can become to thin and smoke a little causing the engine to burn oil.  The usage of oil will become exaggerated  once tuned, under extreme conditions after a good hard run its very common for the tfsi to smoke on idle fro the tail pipes for a few seconds. To eliminate this issue we recommend only to use 5w40 oil Quantum Platinum or 5w40 Millers Nanodrive. If you are planning track days then the best option would be use the Millers 50 grade oil.

5: Which fuel should I use in my 2.0TFSI?

The TFSI engines are designed to run on decent quality fuel (as stated on the fuel filler flap) Using the wrong cheaper low RON fuel is will lose you mpg and power even with the stock factory power.   To get get the best safe power you must run decent higher ron fuel above 98ron. V-power Nitro or Tesco 99 will give the best results and we will only tune if the car is running 98+ and the owner has full intention to use it all the time.  It is false economy to use cheaper low RON fuel on a tuned engine.

Below is a video showing RON fuel tests using a stock  Ed35 TFSI under controlled conditions. The tests show the average HP gains/losses between each fuel.  But the actual peak results where 13hp/13lbft between the Asda 95 and the Vpower. We carried out these tests with 5th Gear and was broadcast on the Discovery Channel.