Badger5AH Fabrications
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  1. #1
    K7ERG's Avatar
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    Project 1.9tdi AHU power upgrade

    Let the new project begin.

    Looking at doubling it 90bhp at least.

    Looking at different turbos GT1749, BV43 etc
    0.216 diesel nozzles/injectors
    URS6 standard intercooler with increased pipework.
    2.5" downpipe/system with No cat (if possible) depending on MOT.........
    Remap of some sort.

    Anything else anyone can suggest then i am open to suggestions


    Thanks in advance
    Audi A6 2.5 5Cyl tdi Quattro running 180ps 370Nm @0.9bar soon to be over 200ps

    AUDI URS4, URS6 and A4 1.8T breaking Lots of spares available at good prices. Large parts require collecting.

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  3. #2
    "Stick a V8 in it!"

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    From what i've read on other users with 90hp engines, you really want to replace the ECU and wiring harness with one from a 110hp engine, as thats capable of running a VGT turbo, whereas the 90hp turbo is wastegated.

    Probably talking 11 or 12mm pump
    Big injectors
    BV43 turbo
    Big intercooler

    2000 A4 1.8T Sport Quattro Avant, Berry Pearl
    2000 A4 1.8T Sport Quattro Saloon, Black-ish
    1997 S4 - PPC £999 Challenge Track Car Build
    TD5 Land Rover Defender build


  4. #3
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    11 mm pump from AHH audi a4 1.9 tdi, bv43, bosio race 520 and AFN ECU will get you to 180 Bhp. Spend a few hundreds notes on a quality clutch and you'll be smilling... I will suggest ported head, 11mm pump with 12mm head, lift pump, Titan nozzles, large turbo and pd 130 head bolts should get you nicely over 180Bhp...
    FOR SALE:
    -Golf mk 5/audi a3 1.6 FSI fuel pump, brand new genuine part boxed + seals
    -audi a3 (1998 to 2003) genuine clutch slave cylinder to fit 1.6 engines BRAND NEW
    -Rear bush press tool to fit new rear axle bushes on Golf Mk3/4, Audi a3/S3, Seat Leon/Toledo, Skoda Octavia mk 1/2 used once

  5. #4
    "Stick a V8 in it!"

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    Wasnt there a downside to going to the 12mm pump?

    2000 A4 1.8T Sport Quattro Avant, Berry Pearl
    2000 A4 1.8T Sport Quattro Saloon, Black-ish
    1997 S4 - PPC £999 Challenge Track Car Build
    TD5 Land Rover Defender build


  6. #5
    OldRedEyes's Avatar
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    Watching this thread with much interest, i used to work with a french lad who had a golf diesel which would eat VR6's for breakfast, and that started life with a lowly 75 bhp!!

  7. #6
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    The 12mm heads are ussualy off low revving diesel engines but they rev fine over 3.5k. Its only when running them to the redline that they are suffering. A 11mm pump gives a 20% power increase across the rev range. Large pump heads don't like small nozzles and they need a little 2 stroke oil to keep them lubricated. I have ported a AHH head (fitted vitton seals, twin springs setup, titanium retainers, lapped the valves in) and i will mate-it to a worked engine block. I have a set of rosten rods and pd 2.0 pistons but i think they are overkill for what the engine can do. I also have a GTB2260vk turbo, a mapped ECU with socketed chips (still in 2 minds if to use this as the AHH a4 i have does have a flashable ECU so really need to find a decent remapper for a "custom" tune). Need a good clutch (will go for s2 240mm clutch and solid flywheel from AHU engine) and waiting for Ryan S of tdi forum to build a custom manifold to fit the turbo on longitudinal engines (he's allready built one for transverse engines- work of art though !). The stock airbox wont fit anymore so CAI will be needed. All this nice lot (AHH has stock 11mm pump) + Bosio race 520 will go into my a4 tdi quattro sport wich curently has a worked v6 tdi engine ! I have been looking to build a 1.9 tdi quattro sport for quite a while and even bought a really tidy 98 avant 2 months ago but i could not put up with just 110 Bhp and poxy 5 speed gearbox ! I know that you should not build a car you can buy but there are no 6 speed 1.9 tdi that i know of ! The v6 tdi quattro sport has strong Getrag 6 speed gearbox with larger axles, the suspension is fully sorted, just had a full respray and i have the show to match the go ! Will start a build thread soon... I have a full donor 1.9 tdi car wich will supply all the parts as most front end bits need replacing: subframe, engine wiring loom, fuel pipes,front lock carrier,etc. I will need to fabricate a downpipe from scratch...










    FOR SALE:
    -Golf mk 5/audi a3 1.6 FSI fuel pump, brand new genuine part boxed + seals
    -audi a3 (1998 to 2003) genuine clutch slave cylinder to fit 1.6 engines BRAND NEW
    -Rear bush press tool to fit new rear axle bushes on Golf Mk3/4, Audi a3/S3, Seat Leon/Toledo, Skoda Octavia mk 1/2 used once

  8. #7
    6th Gear

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    GTB2260VK turbo and Eibach springs for 1.9 tdi (50 quid of ebay brand new full kit to fit passat 4 motion 1.9 tdi) i only needed the fronts as the rears are allready Eibach. Still in 2 minds as to wich turbo to fit, i might as well keep the gtb 2260 for the allroad and use the VNT20 off the allroad and buy a manifold off ebay designed for 8v VAG diesels- its quite pricey though but i think the gtb is overkill for the AFN 110 Bhp engine...


    FOR SALE:
    -Golf mk 5/audi a3 1.6 FSI fuel pump, brand new genuine part boxed + seals
    -audi a3 (1998 to 2003) genuine clutch slave cylinder to fit 1.6 engines BRAND NEW
    -Rear bush press tool to fit new rear axle bushes on Golf Mk3/4, Audi a3/S3, Seat Leon/Toledo, Skoda Octavia mk 1/2 used once

  9. #8
    K7ERG's Avatar
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    Trip to the local scrappys to find a afn 1.9 tdi for some parts.
    Audi A6 2.5 5Cyl tdi Quattro running 180ps 370Nm @0.9bar soon to be over 200ps

    AUDI URS4, URS6 and A4 1.8T breaking Lots of spares available at good prices. Large parts require collecting.

 

 

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