1.9TDI Power Upgrades

[mercedeslimos]

Hi all, aside from my 6-speed quest (another thread),

looking for more power from my 1.9TDI 105 than a remap can give.

As far as I can gather the turbo in mine is a KKK BV39 (correct me if i'm wrong).

What turbos are a bolt-on upgrade? Or better of hybrid. Looking for about the 170ish mark.

PD130/PD150 injectors ore anything better than these?

De-cat and free-flow silencer(s - going for 2 170TDI style)

Front-mount intercooler needed? Mine looks fairly bloody big from what I can see!

And last of all getting the power down, I have a 5-speed box, looking to change to a 6-cog box and clutch & flywheel.

All opinions welcome..

Sam

[martin1810]

Hi all, aside from my 6-speed quest (another thread),

looking for more power from my 1.9TDI 105 than a remap can give.
If you go down this road be careful. In the long run it will be cheaper to buy a different car.

As far as I can gather the turbo in mine is a KKK BV39 (correct me if i'm wrong).
Depends on chassis number

What turbos are a bolt-on upgrade? Or better of hybrid. Looking for about the 170ish mark.
A remap with standard turbo and bigger injectors will probably be happy with current turbo to 150/160 region.
Hybrid turbo...make sure you get it from someone who knows what they are doing.

PD130/PD150 injectors ore anything better than these?
Your injectors will allow a remap to about 130 bhp. although some may claim more.
To go over 130 bhp to the 150/160 region you will need the injectors from a 130/150.
wirh a remap
De-cat and free-flow silencer(s - going for 2 170TDI style)
De-cat etc will make slight difference but you have to make sure remap takes this into account.
Front-mount intercooler needed? Mine looks fairly bloody big from what I can see!
Standard intercooler is fine.

And last of all getting the power down, I have a 5-speed box, looking to change to a 6-cog box and clutch & flywheel.
I think the six speed box is poinless but that is up to you.
If you are serious about 170 bhp area you will have to think solid flywheel and clutch unless you are careful.
Diesels develop a lot of torque at low rpm (say 2500 rpm) that can wreck a clutch in no time.
DMF can let go and smash it's way out of bell housing.

If you go ahead with all this be very careful who you get to do the mechanical and remap work.
Lots of people make claims that they can't back up.
Have fun.

All opinions welcome..

Sam

See above

[mercedeslimos]

thanks for your input Martin not really well-versed on upgrades for the PD, this is my first one after a succession of VE tdi'd cars.

in honesty buying another car is not an option, as i only have her a few months. she was my parents car before me and they'd kill me if i sold up (got her as a family deal for half retail value very cheap) nice low miles, love the colour and that i know she's never wanted for anything, been religiously serviced and looked after like a baby. and the fact I've already done a raft of bits and pieces to her to make it my own. and love the way it drives tight as a drum, no point in buying another one that you have no idea about the car, god knows I'd end up tuning that anyway! and I'd definitely regret selling this one! oh and the way the Irish tax bands work, for every 100cc over 1600cc, the tax goes up by fifty-seventy euro a year. if i got a TDI I'd be looking at doubling my insurance premiums and paying over a hundred euro more in tax a year!

I have a fast 9A'd Royal Blue MK2 so this is my fast daily driver, want her to be some-ways reliable.

how would i find out what turbo i have from the chassis number?

i wouldn't be happy with just a remap, and knowing that i have the money I'd rather spend it in one hit rather than draw it out slowly doing it up, as there are no real places that specialise in tuning VW's, never mind TDI's here!

For the turbo, was thinking that 150 turbo would be expensive and hard to come by.
was looking at Darkside Developments GTB turbo kits, specifically the 1756VK, rated to 230HP.

i want this car to be faster than my previous rover SD turbo, running 149HP and a real shed lump of torque, imagine pulling up a 1 in 2 hill in 5th kind of job.

injectors, so 150 and 130 are the same, imagine they're not too hard come by, if they give enough for 170ish

the reason why i want 170 is my other half is in the process off buying anew car. most likely a new MK6 GTD. Can't have my car trailing behind miserably!

As for de-cat i have a friend who deals in making sump-guards and doing exhaust bits and pieces who can knock me up a flanged de-cat. would taking either of the other boxes out be beneficial? i want a car that sounds not half bad but none of that awful cooing pigeon sound!

intercooler wise, i like the idea of having nice intercooler just visible behind the bumper, nice and mean but stealthy too. mate has a MK2 16VT and that's the only clue all that glitters is not gold... until the boot goes down that is!

and lastly for the transmission, a six-speed is just a cool thin, i'd like telling people i have a six-speed! oh and the car it's in was water damaged and worthless, box conversion would work out rather cheap.
as for DMF, a solid conversion would be in order with a nice fat clutch to keep things in check! when i did in my rover's turbo running big boost and loads of fuel really home-brewed job!, when the turbo died i swapped it for one from a 600 with a bigger compressor and could run higher boost. i could get the same power running 20psi on the 600 turbo than i did running 24psi on the 220 turbo. new turbo on and re-bored injectors with a lower pressure and bigger nozzles. i killed the clutch in about 3 weeks, replaced it with a flywheel and cluthc kit from a 600 as well, an in-house conversion for peanuts.

and for the map, have a very very good guy up in Dublin who is a live mapping genius!

mechanically wise i'd buy everything as kit or secondhand or whatever, piece it together, and have a mechanic mate who builds fast turbo'd VW's to do the work at mates rates.

gimme your thoughts!

Sam

[mercedeslimos]

http://www.vvt-motorsport.nl/