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  1. #1
    DieselJake's Avatar
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    1.9tdi 220bhp and 360ft/lbs support mods (A4 B6 1.9 130)

    Getting a new turbo and map soon, should be pushing around 220bhp and 360ft/lbs. After looking into clutch kits I'd prefer DMF because it seems single mass can cause other problems, plus chatter would bug me. Only issue is I'm not sure how DMF's hold out as Sachs is rated 350ft/lbs(+?), can anyone confirm whether this will be fine or if there's better alternatives, SMF's may be ok if you can recommend a good one. Thinking of going for a side mount intercooler to keep a stock look but not sure this is ideal either. Thinking for brakes it'll be 312mm front and 282mm rear. Just wanted some input and to see if anyone could point out other things necessary to support the power.

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  3. #2
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    Sachs SRE uprated pressure plate and organic clutch disc. Is your's a 228mm clutch or 240mm clutch ? What turbo you're getting, do you know the specs ? 220Bhp is rather high on factory pd130 nozzles especially if you want a clean tune ! If you have a 5 speed gearbox i would forget about single mass flywheels and cap the torque at max 350Nm or the box won't play ball for too long ! The 5 speed boxes in later audi are rather ****e !
    FOR SALE:
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  4. #3
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    Cheers, not too sure on clutch size but organic clutch and Sachs uprated pressure plate definitely seem the best way to go, was just worried encase this wasn't enough. Turbo's GTB1756V at the mo' unless I change my mind in the mean time, no idea on turbo spec's, tried judging it from other people's experience but hard to find many reviews. Thanks, was thinking the nozzles may be a weak link but was just trying to be cheap (well all this is expensive but my current turbo and clutch are on there way out so thought this would be the best time to upgrade). Yeah it's a five speed, probably best with a cap actually never even thought of that, cheers, worried about the box now.
    Last edited by DieselJake; 6th October 2013 at 16:37.

  5. #4
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    Swaying towards S3 intercooler now instead, seems cheaper and simpler.

  6. #5
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    gt1756v will surge a lot on a 1.9Tdi, you might want to look into the GTB series...A bv43 is a better choice for your engine and it's plug and play !
    FOR SALE:
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    -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

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    Cheers, does sound like a better idea, guessing the bv43 will spool quicker too? I'm useless with turbo's, think I'm just chasing performance figures instead of thinking logically. Looked a bit more into surges and from what I gather 3rd gear plus with WOT would be where it would happen, not ideal and guess it's hard to judge how long the turbo would last with surges.

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    GT17 turbine shaft has the "slender look" which means the shaft is not solid but machined (has a notch)- it's there where it snaps ! 56mm compressor wheel is rather heavy and a poor match for the small hotside- you will need a small inducer on that wheel in order to flow air for 220Bhp ! Even gtb1756Vk which is a latest generation VNT turbo is struggling to flow enough air for 240-250Bhp ! Also the chra is solid metal and not alloy/cast steel like in the gt17 series ! With high pr it will break... BV43 is a nice little turbo, still a bit laggy but you can live with it especially if you make the VNT rod a little shorter and the N75 duty cycle is massaged a bit in the tune !
    Big numbers is irrelevant for a daily driven car...
    FOR SALE:
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    -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

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    Thanks, that all sounds about right, guessing the later generation are better suited and more stable. Need to read up on this more before I take the plunge, will join tdi club and see if I can absorb any more information. BV43 definitely seems ideal for daily driver reasons as you say but I'm having trouble finding one, plan was just to leave it at Darkside Developments for a few days because me and engine bay's don't work well together. Could go for a later generation GTB2260VK but then to make the most of it I'd need bigger injectors and single mass which again leads to the problem of killing the box and probably some other problems I don't know of, hopes of a daily driven car would more than likely be down the pan too.

  10. #9
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    Gtb 2260vk is too big, a gtb2056vl is much better suited to the 8v engine however i would look for a gtb1756vk if you want similar to stock response and decent top end... The larger the turbo the less responsive becomes which is not too bad in some cases but the 1.9 tdi does not have enough volumetric efficiency without working the head and the injectors are big money ! I would say keep it simple and if you get a hybrid do not go for bigger than 52mm compressor wheel to keep surge to minimum ! bv43 is plug and play, i have one if you need- can fit and map the car for you as well ! Drop me a pm or give me a call one day to discuss. Regards,
    Chris- 07789912128.
    FOR SALE:
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    -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

  11. #10
    YSN
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    Would 200bhp be ok with stock pd130 nozzles and a bv43 turbo for a daily driver?

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    Yes mate, 200Bhp will be nice on the car, however the clutch will struggle to hold the torque especially in high gear low speed situations...
    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

  13. #12
    YSN
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    Isn't that dependent on the driver though? for example if you be sensible about it you wouldn't boot it in high gear low revs as the torque will stress the clutch out etc. Where abouts in london are you Chris I might take you up on mapping my car if your local to me.

  14. #13
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    Quote Originally Posted by YSN View Post
    Isn't that dependent on the driver though? for example if you be sensible about it you wouldn't boot it in high gear low revs as the torque will stress the clutch out etc. Where abouts in london are you Chris I might take you up on mapping my car if your local to me.
    N. London...
    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

  15. #14
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    I have a BPX engine, im about to fit an ARL golfs FMIC. Im looking for a turbo upgrade too, i figured the ARL turbo would suffice, however you are all quoting numbers and im baffled all over again... also wondering how mapping will work given the engine having a bigger turbo and injectors in stock trim, with my ASZ ecu.
    '02 TDi 130 Sport: Mods to date: BXP 160 conversion, EGR delete, Decat, Helix SMF fast road clutch, 312mm front rotors, full DIS , CC, Xenons.
    VCDS fully registered and happy to help.
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