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Update. I went back a checked everything again. Did a vacuum test on the EGR. It turns out this was not holding vacuum. So I suspect that when the EGR tried to open then it effectively caused a vacuum leak in the system which affected the turbo actuator. I put the old one back in and things...

My problem is that the engine seems to be going into limp mode. It will not go above 2,000 rpm (well not by much) No CEL. No fault codes on the engine. Audi A4 (b5) 2.5 TDI (engine code AFB) Engine was completely rebuilt. New cams, new oversized pistons/rings, all new bushings, new exhaust...

I have done some power enhancements. Installed the Bosio PP683 injectors set to around 180 bhp and had the ECU tuned to work with the larger injectors. Car runs nicely. Would using one of your hybrid turbos be beneficial with my current setup? or would I also need to retune the ECU? I had it...

Part 2 - To improve the exhaust further I removed the center muffler (which weighs some 25 lbs) and replaced it with an aftermarket DPF. This filter does not require the computer generated regeneration, but does it passively when hot enough and run long enough at higher rpms - periodically. It...

After converting from US gallons to UK gallons I am seeing a range from 29 to 41 mpg. So right in line with the earlier posters. Does anyone know the capacity of the quattro b5 fuel tank? I am seeing the light come on at around 11.5 UK gallons and am wondering if the pump in the tank that...

Update - I was able to make the precat work on the b5. I had to deform the vacuum pump heat shield about 3 mm to keep it from touching the cat. Other than that there were no clearance issues. It was not too difficult. See post #27 at this link for photos/description...

Thanks, I do have one set of spare cats. with downpipe - although somewhat clogged at the front of the cats. (seen through a boroscope). Cleaning suggestions? On the set on the car I ended up cutting the pipe open to clean, although I suspect I may have ruined the cats trying out various...

Thanks for catching that. I believe you are correct. The manufacturer did not distinguish between the AWD and FWD manual transmissions. Do you think the b6 pre-cats (that attach directly to the turbo) would fit? The space looks a bit tight, but I can't imagine the firewall / trans. tunnel is...

I have recently converted my 2001 Audi A4 b5 Avant Quattro 1.8T into a 2.5 TDI with the AFB v6. These are not available in the US - hence the conversion. I currently have the stock exhaust system with the two catalytic convertors. The cats were mostly blocked up so I cut the pipe and cleaned...