darkside tunning ??? Safe to tune a 105 bhp 1.9tdi

[Onemorerep]

Iv got an 1.9tdi pd105bhp and wanting more power is it worth upgrading it or will i just have problems iv spoke to a company i got put on to called darkside and they said they can have it running 260bhp at a cost of 4.5k any one got any opinions sensible ones obv lol

 

[Gazwould]

What engine code ?

 

[desertstorm]

Question is how much power do you want and how much do you want to spend.? Does the 4.5K include brake and suspension upgrades ?.
Darkside can get big numbers out of diesels by changing the turbo, putting bigger injectors in a bigger FMIC and modified exhaust. You would also need a Sachs organic clutch to handle the power.
I should imagine that price includes new rods/ big end bearings as the 105bhp engines seem to have issues even at standard power levels.

 

[Bedders]

As GAZWOULD asks above....what's version of the 1.9tdi have you got? If it the one with the BXE code engine I'd just sell it & buy another car / version with more bhp as standard. These with the mentioned code smash con-rods very frequently with the standard 105bhp. Smashes through the side of the engine block & completely totals the engine. You gonna run 260bhp through those con-rods?

AS DESERTSTORM comments check if uprated conrods included in your quote.

 

[Onemorerep]

I emailed enquiring about the upgrades and they sent me this as im not to knowledgable about it i thought id ask the people on here thanks

Thanks for emailing. Here is a breakdown of our DPF Delete options:

Gut Stock DPF Downpipe, Remove Faults and Custom Remap to ~145bhp - £650 + VAT = £780

Stainless DPFDelete Downpipe, Remove Faults and Custom Remap to ~145bhp - £750 + VAT = £960
http://www.darksidedevelopments.co....2-0-tdi-16v-pd170-ppd170-cr140-and-cr170.html

For the EGR and Cooler Delete added £100 + VAT to these prices. We do normally advise this at the same time as the DPF Delete.

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Turbo Upgrade
Here are the list of parts needed to get to ~260bhp. Prices are + VAT

Engine
GTB2260VK Turbo Kit with Tubular Stainless Manifold and 3" Downpipe - £1900 - http://www.darksidedevelopments.co.uk/products/darkside-gtb-turbo-kit-for-1-9-8v-tdi-engines.html
Race Injectors - £600 + Surcharge - http://www.darksidedevelopments.co....-8v-tdi-with-firad-50-80-120-160-nozzles.html
Injector Bolts - £65 - http://www.darksidedevelopments.co....-bolt-kits-for-1-9-2-0-8v-tdi-pd-engines.html
PD150 Head Bolts - £30 - http://www.darksidedevelopments.co....d-bolt-set-for-1-9-2-0-8v-tdi-pd-engines.html
Intercooler and Pipe Kit - £350 - http://www.darksidedevelopments.co....it-fmic-for-bls-brm-bmp-bmm-inc-caddy-2k.html
EGR Delete - £75 - http://www.darksidedevelopments.co....v-tdi-pd-ppd-and-cr-egr-delete-race-pipe.html
EGR Cooler Delete - £8.50 - http://www.darksidedevelopments.co....for-1-9-8v-pd105-2-0-16v-tdi-pd140-pd170.html4 BAR MAP Sensor - £45 - http://www.darksidedevelopments.co....map-manifold-pressure-sensor-03k-906-051.html
Rocker Gasket - £12.50 - http://www.darksidedevelopments.co....ver-gasket-for-1-9-2-0-tdi-8v-pd-engines.htmlCustom Exhaust System - £350 + Any Silencers & Tip Options - http://www.darksidedevelopments.co.uk/products/darkside-developments-custom-exhaust-systems.html

Fitting of above - £400
Custom Mapping - £500

To get to ~280/290bhp you then need this

Race Camshaft - £750 - http://www.darksidedevelopments.co....e-camshaft-kit-for-1-9-2-0-8v-pd-engines.html
Cam Cap Bolts - £50 - http://www.darksidedevelopments.co.uk/products/cam-cap-bolt-kit-for-1-9-2-0-8v-tdi-pd-engines.html

Gearbox
6 Speed Swap - Ideally with this power you want to swap for a 6 Speed setup from a PD140 / PD170 as the 5 Speed is very weak. If you did that, we then have the following clutch and diff options, if you want to supply us all the parts, we can fit at the same time -

Again running this power we normally advise a 6 speed gearbox.

6 Speed Conversion is £515 + VAT and fitting.

Once it is 6 Speed, you need the following

Darkside SMF & Organic Kit - £750 - http://www.darksidedevelopments.co....ywheel-smf-clutch-kit-for-vw-02q-6-speed.html
Quaife Limited Slip Diff (Optional) - £705 - http://www.darksidedevelopments.co.uk/products/quaife-02q-2wd-atb-helical-limited-slip-diff-lsd.html
Clutch and Gearbox Fitting - £240
Diff Fitting (Optional) - £200
Gearbox Oil - £45

VRM:
Full Vehicle Details:
VRM:
Make: AUDI
Model: A3 Sportback
Model Version: 1B (7/2008 - 3/2013)
Manufacturer Version: 8P
Derivative: Sport
Description: A3 E SPORT TDI
Steering Position: Right Hand Drive
Body: Hatchback
Doors: 5 Doors
Drive: Front
Transmission: Manual
Gears: 5 Gears
Engine Size: 1.9 litres
Exact CC: 1896
Fuel: Diesel
Fuel Delivery: Turbo
Valves: 8 Valves
BHP: 103
KW: 76
Engine Code: BLS
Cylinders: 4 Cylinders
Weight: 1880kg
Others:
VIN
Engine Number: BLS 798585
Registered Date: 19-MAY-2009

 

[Bedders]

I'd just do a google search for the BLS engine faults & make a decision from there

 

[desertstorm]

Well your car has a BLS engine, this is essentially the same as the BXE which is the one that has lots of issues. Just Google BXE rod failure.
They have the same rods and big end . The problem appears to be with the big end shells breaking up, blocking the oil ways and eventually the big end will fail usually resulting in the rod snapping and wrecking the engine.
http://www.partsbase.org/audi/audi-a3-s3-sportback-qu-a3-eu-2009-10550-crankshaft-conrod-bearings/

 

[desertstorm]

The older 1.9 PD engines were pretty much bullet proof. A standard 130 bhp engine could go to 300 bhp with a standard bottom end.
There is no mention of brake upgrades or suspension upgrades. If you had 260 bhp and a load of torque you would be spending a lot of time spinning the wheels without a LSD.
As they say the 5 speed box is weak and the standard clutch certainly wouldn't cope with the extra torque.

 

[Onemorerep]

Thanks guys atleast now i know not to bother can i not just put something bigger in it engine wise ?? I dont really want to get rid iv just bought all black edition front and rear bumpers and door trims ash tray and gear stick surround , whole roof lining and pilar kit ,new gloss black rotars new drl headlights and had the windows blacked

 

[SnazzyWafles]

Sorry to steal your thread bud, how much did the interior stuff set you back? I'm getting very bored of the light gray roof lining!

Also a bit more on subject, with anything, it's up to you how much you want to spend and there's always the question "do I upgrade what I've got or buy better". If I was in your position I'd stick it out and wait for a better platform to build on, or aim for slightly less power and veer on the safe side. That being said, if your do end up getting 260bhp out of it, post some videos up so we can all have a right good nosy

 

[desertstorm]

Because of the issues this engine has I personally wouldn't even map it. I know they have done them at Darkside
http://www.darksidedevelopments.co.uk/seat-leon-mk2-1-9-8v-bxe/
The car above is a BXE but it's had new pistons, rods, bearings etc .
If you want a performance diesel get a better starting car, something like a 2.0 170 TDI quattro.
http://www.autotrader.co.uk/classified/advert/201511228909417
A hybrid turbo, DPF delete and a map on this would get you to around 230bhp and cost about £1400 but not from Darkside.

 

[Onemorerep]

Thanks boys ! Il most probably just leave the engine and drive the car for a bit and sell it when im bored the roof and pillar kit cost me about 250 out of a black edition iv not put any of the stuff on the car except the screen and window tints i might just swerve putting it all on and get rid of the car