1997 audi a4 1.9 tdi tuning?

[Broomhall88]

Hi all, I just brought a 1997 audi a4 1.9 tdi AFN. I think its the 110 bhp model as it has the red "i" Anyways im wanting to upgrade the performance in the near future when i have a bit more cash but i haven't got a clue where to start lol. what do you guys think the cheapest option would be to start with? sorry if its a newbish question im just looking for a bit of advise as you guy's seem to know what your talking about. Thanks :)

[zollaf]

welcome to the forum.
there is a member, hibsy 21, iirc , just done some mods, and others as well that are in the know, but i think you can do bigger injectors, bigger pump head, different chip and a bigger turbo, even a vnt for more low down grunt, and even a bigger intercooler. they are quite quick to start with, so first make sure yours is running as it should. clean the manifolds and intercooler, get rid of the egr valve and cat/filter thing in the exhaust, new timing belt and dial in the timing etc....
its amazing how much gunk and soot can be in those things and cleaning lets the air flow which improves power.

[Broomhall88]

Thanks for the welcome and speedy reply! :) It is pretty quick already to be honist but there's nothing wrong with wanting a bit more power XD I think the first thing i will do is give the manifolds and intercooler a good clean out, then de-cat the exhaust and mabie think about getting a re-map later on down the road. :)

[zollaf]

thats all i have done to mine so far. amazing amount of gunge in the inlet. i scraped out what i could and burnt the reats out with a blowtorch. the cat was 50 % blocked as well.

[Broomhall88]

Whats the best way to de-cat the exhaust? should i just take it off and knock out the guts or should i get a already de-cated section?

[zollaf]

either will do. i made mine, just cut the cat out and welded a pipe in its place.

[Broomhall88]

Ok once again thanks for the advise, its much appreciated! Great forum by the way, im sure i will learn lots of tips/tricks on here. Cheers

[zollaf]

you are welcome and yes, this is a great forum :)

[NSNP]

Ok once again thanks for the advise, its much appreciated! Great forum by the way, im sure i will learn lots of tips/tricks on here. Cheers

Great advice from Zollaf, starting from a clean base is always a good way to go. When we deleted the EGR valve the crap that was in there was ridiculous, at least a 40% reduction in airflow.
The PD engines are very versatile and as suggested, the cheap mods are de-cat + mufflerectomy (removing the backbox and replacing with a straight pipe), EGR delete and a remap. That should see you somewhere around 160bhp and a decent boost in torque too. Beware of aggressive maps though, the dual mass flywheels aren't up to much so you may find upgrading that is a necessity once you begin fettling.

Then your options are directly proportional to the depth of your pockets!

- Hybrid turbo
- Big turbo
- Larger Intercooler
- Hard boost pipes
- Water methanol injection
- Bigger injectors
- Head work

One of the most fettled TDIs we've seen is the Darkside Jetta:

http://youtu.be/-H5RDufR5xU

That's running over 300bhp with 156mph top speeds!

[adamss24]

The easiest way to tune the AFN engine is by trowing a large set of nozzles, fit a GT1749VA or BV43 turbocharger, and have a chip tune. On your 1997 model the MAP sensor is located on the ECU and is not easy upgraded, on the later models it's on the boost pipe from the intercooler to inlet manifold and easy to swap to a 3 Bar item. I have had a w reg audi a4 saloon with a rare AHH engine, it's a 90 Bhp engine in standard trim but has very tiny nozzles, a VNT GT1749V turbocharger (every other 90 Bhp is wastegated GT15) and has 11mm pump which can generate more pressure than the standard 10mm pump. I have aggressively ported the head, fitted forged aftermarket rods, twin valve springs + titanium retainers, PD 130 lifters, PD 150 Bhp head bolts (higher tensile strength), had a set of Bosio race 520 nozzles fitted to AEL injectors bodies and it was running over 200Bhp. I crashed the car so i had to pull the engine off as i was planning to use the lump into a v6 tdi quattro due to the fact that it has a very strong 01E 6 speed gearbox and propper 4 wheel drive and has the added bonus of using a 240mm clutch. On removal the stock flywheel was mulered and it was cutting into the flywheel bolts + the stock clutch (used to slip with the GT1749VA turbo but no slip with the bv43 !) had every spring broken due to the torque generated. The little a4 was so fast i had a play with a mates corrado vr6 and he could not believe it was faster than him up to 80-90 Mph ! Here's 2 little clips i made shortly after the engine rebuilt, please note the engine wasn't revved over 4k as it was still tight + i was on the stock new Sachs clutch and original inlet + turbocharger !
http://i840.photobucket.com/albums/zz323/adamss24/12-1.jpg
http://i840.photobucket.com/albums/zz323/adamss24/13.jpg
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http://i840.photobucket.com/albums/zz323/adamss24/DSCF3104.jpg
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http://i840.photobucket.com/albums/zz323/adamss24/DSCF3089.jpg
http://i840.photobucket.com/albums/zz323/adamss24/largeinjectors.jpg
http://i840.photobucket.com/albums/zz323/adamss24/head2.jpg
http://i840.photobucket.com/albums/zz323/adamss24/head1.jpg


Video's, click on the link:
http://i840.photobucket.com/albums/zz323/adamss24/th_060711-1841.jpg (http://s840.photobucket.com/albums/zz323/adamss24/?action=view&current=060711-1841.mp4)

http://i840.photobucket.com/albums/zz323/adamss24/th_littleclip.jpg (http://s840.photobucket.com/albums/zz323/adamss24/?action=view&current=littleclip.mp4)

[adamss24]

http://i840.photobucket.com/albums/zz323/adamss24/250711-2019001.jpg
http://i840.photobucket.com/albums/zz323/adamss24/250711-2019.jpg
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http://i840.photobucket.com/albums/zz323/adamss24/250711-2019003.jpg
http://i840.photobucket.com/albums/zz323/adamss24/gtb2260vkvsbv43.jpg
http://i840.photobucket.com/albums/zz323/adamss24/bv43vsgtb2260vk3.jpg
http://i840.photobucket.com/albums/zz323/adamss24/DSCF3725.jpg
http://i840.photobucket.com/albums/zz323/adamss24/DSCF3799.jpg
http://i840.photobucket.com/albums/zz323/adamss24/DSCF3800.jpg
http://i840.photobucket.com/albums/zz323/adamss24/PD150_0021.jpg
http://i840.photobucket.com/albums/zz323/adamss24/IMG_06771.jpg

[zollaf]

i am suprised to see you run that engine with a cat on it :)

[Broomhall88]

Thanks guys, I took it for a good spin today and was impressed with the pulling power even in 4th and 5th gear! :D I have been looking at turbos but most of them cost more than i payed for the car lol (£300) so i dont really fancy spending hundreds on it, i would rather save the money and put it towards a smarter audi and put more money into tuning that one up.
Do you guys think it would be a good idea for me to blank off my EGR? EGR Valve blanking plate 3mm Steel VW SEAT SKODA AUDI FORD T3 T4 T5 R6 TransT25 | eBay (http://www.ebay.co.uk/itm/110908091425?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649#ht_931wt_1037) This is the blanking plate i have seen recommended on another thread, but i have also seen that its not a good idea to blank it on a PD engine and im not sure if thats what my engine is :s Any help would be much appreciated :)

[adamss24]

i am suprised to see you run that engine with a cat on it :)
To be honest i just wanted the engine to run as i had plans to get it into a better chassis so i did not bother with the inlet manifold or the catalyst. I even let the intercooler the same which many see as a bottleneck for sustained power and i did not see any decrease in power due to heat soak !
Gave up with my project and still have the engine and clutch in the shed waiting for the right 1.9Tdi quattro ! The clutch is a special rs4 solid billet flywheel which is made of CrMolibdenum steel and is drilled to fit the 1.8/1.9 Tdi crank. The clutch is a modified Southbend Silent clutch able to cope with over 500Bhp and 600Nm... Mighty clutch for an engine with over 250Bhp potential. The funny thing is that at the time- in the clips- the engine was still running the 90 Bhp map !!!

[hibbsy21]

there is a member, hibsy 21, iirc , just done some mods,

You do remember correctly. Turbo is on now and boosting nicely, underboosting under load in fifth though. Tweeking of the actuator will be done this week after the MOT.

But as said above, get rid of the EGR, clean out intake manifold. Clean MAF sensor with brake cleaner. Use a hair dryer to get all the sludge out of the intercooler (just hold it in one side and let it heat up and the crap will start pouring out, a thick black slime).

Bin the cat and get a decat downpipe. I believe there is one on ebay at the moment with a CAT shaped bit on it so you wont fail MOT.

But again, make sure you give it a major service before you start doing stuff. Timing belt is a must!

Rich

[Broomhall88]

Thank you :) i did take the EGR off today to give it a clean (thought it wouldn't do it any harm) there is alot of thick black slime in the intake manifold pipes. i didnt take it off as i have work in the morning and didnt want to get ahead of myself. anyway i ran into another problem :S i thought i would disconnect the pipe on the back of the manifold to have a look inside and noticed that the rubber connector with 2 jubilee clips that connects the pipe to the manifold has a massive hole on the bottom of it! :( Is it a bad idea to keep driving it like this or mabie i could use some duct tape to seal it untill i get a new one? also what is the name of that rubber connector so i know what to look for? sorry im a complete noob when it comes to engines lol heres some pics. 1736217363

[zollaf]

thats the pipe that connects the turbo to the manifold via the intercooler, it provides the engine with compressed air ( 10 - 15 psi ) and is why its quite powerful for a small diesel engine. most of the air will be going straight out through the hole. i think you will be pleased when its repaired. you could get a short length of silicone turbo hose of the right diameter to replace it with though. its probably 2'' internal and is a common and easy to get size.
something like this, but probably from a seller not across the other side of the world. sorry, first one i could find. 2" TURBO INTERCOOLER BLUE SILICONE HOSE SILICON COUPLER | eBay (http://www.ebay.co.uk/itm/2-TURBO-INTERCOOLER-BLUE-SILICONE-HOSE-SILICON-COUPLER-/150445081540?pt=AU_Car_Parts_Accessories&hash=item230739c3c4#ht_1192wt_932)

[Broomhall88]

Ok thanks alot! The friend i brought the car off has a friend who owns a car breakers scrap yard and gets the bits for free. Thats where i got my new carpet from because i had water coming in but thats all sorted now. hes got 2 a4's out there atm so he is going out there tomorrow to see if he can get me one. :)

[zollaf]

cool, should make a difference. its ok to drive, just dont use the turbo any more than you can help.

[Broomhall88]

Im just gonna wrap it up with duct tape so i can get to work in the morning untill i get a new one. im getting obsessed with this car lol i cant wait to clean that manifold out, i put my finger in there and there must be at least an inch of gunge on the walls of the pipes.

[zollaf]

get on with it, that gunk restricts air. fit an egr blank as well, theres a guy on ebay sells the plates, should cost about a tenner and you can do away with the valve for it. clean that intercooler whilst you are at it.

[Broomhall88]

EGR Valve blanking plate 3mm Steel VW SEAT SKODA AUDI FORD T3 T4 T5 R6 TransT25 | eBay (http://www.ebay.co.uk/itm/110908091425?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649#ht_931wt_1037) Thats the ones im thinking of buying, i take it i need 2 of them. also when i take off the EGR and blank the pipes off do i take off the silver flexible pipe from the bottom of the EGR or do i just blank it off? do i need to take off the intercooler aswell to clean it or could it be done without removing it? sorry for all these questions but you seem to kknow what you're doing lol

[zollaf]

thats the chap, got mine off him. yes, you need 2 of them. remove the egr from the inlet and the exhaust, including the flexible pipe, and put the plates over the holes that are left. i think you are best leaving the electric solonoid in place and connected and put a bolt in the pipe where it would go into the egr. someone else will tell you if you can remove the solonoid without putting the em light on. best to take the intercooler out to clean it. use diesel, paraffin, hairdryer, petrol etc to get rid of the muck inside it, flush with water, dry thoroughly and re fit. get the outside clean as well. check all the other pipes to it and repalce any with holes. also replace all the thin vacuum pipes as well as these perish and cause problems.

[Broomhall88]

Thankyou so much for all your help! :) Loaded with all the info you have given me i think i should be able to sort it out. its actually quite fun mucking around with the engine, ive never even touched one before only to change oil and water hahaha is the electric solonoid that little rubber hose that just push fits onto the egr?