Putting bigger injectors and turbo into a 90 BHP passat?

xDiabhalx

I'm considering putting a bigger turbo and bigger injectors into my 90 BHP passat, i would be changing the sensors too. I'm just curious to whether anyone else has done this before and had any problems or success? I'm also wondering if anyone knows if the ecu will cause any problems after doing this or should it just compensate automatically with the new sensors in it? It's the 00' model passat.

mike65

Why would you bother? The cost would be greater than buying a 10 year old turbo D with more power.

johnos1984

Why not just get a remap?

barura

Because s/he knows their own car and what condition it's in? Buying a car with that sort of modification used possibly has a lot of problems, modifying their own car will mean they know what is going into it and the history of it.

xDiabhalx

I just want to give the car more power, I want to keep the car, I was considering getting the turbo and injectors from a 110 BHP passat, from a breakers yard, shouldnt cost too much, it could be remapped after giving more power again

Nissan doctor

xDiabhalx wrote: »

I'm considering putting a bigger turbo and bigger injectors into my 90 BHP passat, i would be changing all the associated sensors too. I'm just curious to whether anyone else has done this before and had any problems or success? I'm also wondering if anyone knows if the ecu will cause any problems after doing this or should it just compensate automatically with the new sensors in it? It's the 00' model passat.

What new sensors are you going to fit?


I'd recommend some proper research into how to tune a VAG tdi before you start splashing out on random parts.

xDiabhalx

Is the MAF sensor not different on the 90 BHP than the 110/130 BHP passats?

vectra

Is your engine a Non PD one?
PD Parts will not fit as far as I am aware and if the turbo would fit i am sure there could be quite a lot of other mods needed as well. Possibly have to replace the ECU as well.
Bigger injectors and a remap?
I think at best you could see 125bhp. (stand to be corrected)

xDiabhalx

vectra wrote: »

Is your engine a Non PD one?
PD Parts will not fit as far as I am aware and if the turbo would fit i am sure there could be quite a lot of other mods needed as well. Possibly have to replace the ECU as well.
Bigger injectors and a remap?
I think at best you could see 125bhp. (stand to be corrected)

125, that all you reckon? I know Torquetronix do a remap that gets it to 120 BHP without doing anything else, I thought if you changed the injectors and possibly the turbo you would see more of a difference. Does chipping a car after a remap give more power or does it make any difference?

Nissan doctor

xDiabhalx wrote: »

Is the MAF sensor not different on the 90 BHP than the 110/130 BHP passats?

The MAF may be different(I'm not certain off hand) but it doesn't require changing for any mild level of tune on a VAG tdi.

If you just want 110hp from a 90hp engine, this(and more) could be achieved easily from a proper remap without having to change any parts, assuming the ones you have are in good condition.

unkel

90 BHP so your car is from the 90s, right?

In that case fitting a new turbo alone would cost a lot more than your car is worth. Sell it and buy something with a few more TTDDIIIIS

xDiabhalx

Nissan doctor wrote: »

The MAF may be different(I'm not certain off hand) but it doesn't require changing for any mild level of tune on a VAG tdi.

If you just want 110hp from a 90hp engine, this(and more) could be achieved easily from a proper remap without having to change any parts, assuming the ones you have are in good condition.

I was hoping to get somewhere around 130-135 BHP, a remap alone couldn't get it to that, I was just wondering if changing the turbo and injectors would do the job

unkel wrote: »

90 BHP so your car is from the 90s, right?

In that case fitting a new turbo alone would cost a lot more than your car is worth. Sell it and buy something with a few more TTDDIIIIS

I just did some mods to the car so I don't want to sell it for a while

Nissan doctor

xDiabhalx wrote: »

125, that all you reckon? I know Torquetronix do a remap that gets it to 120 BHP without doing anything else, I thought if you changed the injectors and possibly the turbo you would see more of a difference. Does chipping a car after a remap give more power or does it make any difference?

'Chipping' is usually just McDonalds car park speak for remapping.

Years ago it was common to reprogram the ecu's chip with a generic upgrade map...but this not the way to properly tune a car as every engine is slightly different.

L-M

You could buy this,

http://vagdrivers.net/forums/index.php?showtopic=71917&hl=turbo

Which is fairly good value imo. Also PM Marlow on here, or he might be along to post, but he knows his stuff about what injectors to use on these. I think it's the injectors from a certain model 2.5 TDI that fit. (Very expensive new, though.

You should see around 140 with those bits and pieces.

I was going to buy that turbo myself, but I think I'll leave well enough alone with my own car. I reckon if the turbo was 300, then 350 for a proper map, plus 200 for injectors and lets say 50 for odds and ends, the bill adds up fairly fast.

xDiabhalx

Yeah it does, be delighted to get that out of it though, would a 115 bhp turbo be the best one to go for? what size injectors would you be putting in?

L-M

xDiabhalx wrote: »

Yeah it does, be delighted to get that out of it though, would a 115 bhp turbo be the best one to go for? what size injectors would you be putting in?

I have to go out now but I'll do a search through my posts tomorrow and try find out. If you register on that vagdrivers.net site there are plenty of helpful characters on it!

xDiabhalx

Limerick man wrote: »

I have to go out now but I'll do a search through my posts tomorrow and try find out. If you register on that vagdrivers.net site there are plenty of helpful characters on it!

Sound, I'll register on there thanks

vectra

xDiabhalx wrote: »

Yeah it does, be delighted to get that out of it though, would a 115 bhp turbo be the best one to go for? what size injectors would you be putting in?

Would it not be a cheaper option to buy a 110 pd engine with smaller mileage and map that?
Or better still buy a 130/150 and map that

xDiabhalx

vectra wrote: »

Would it not be a cheaper option to buy a 110 pd engine with smaller mileage and map that?
Or better still buy a 130/150 and map that

How much around would you pick one up for do you know?

vectra

xDiabhalx wrote: »

How much around would you pick one up for do you know?

Have a look on Donedeal.
Better still get registered on vagdrivers.net >> This could take a few days to get approved. so be patient.

The guys over there are always selling stuff and lots of them know their stuff.

On the other hand,
A friend of my son's has a Bora which got a bad enough slap recently is expecting it to be written off by the insurance company.
It has a hybrid turbo and bigger injectors I think. as far as I know it puts out around 180bhp but the owner was not one for driving it hard.

Will check it out over the coming days if you like?
Possibly buy the whole car and use what you need. Scrap the rest.

xDiabhalx

vectra wrote: »

Have a look on Donedeal.
Better still get registered on vagdrivers.net >> This could take a few days to get approved. so be patient.

The guys over there are always selling stuff and lots of them know their stuff.

On the other hand,
A friend of my son's has a Bora which got a bad enough slap recently is expecting it to be written off by the insurance company.
It has a hybrid turbo and bigger injectors I think. as far as I know it puts out around 180bhp but the owner was not one for driving it hard.

Will check it out over the coming days if you like?
Possibly buy the whole car and use what you need. Scrap the rest.

Yeah please do, I'd be interested to see how much he's take for it

Gary ITR

How many miles on your car? Has it ever had a clutch? If irt hasn't budget for one too.

If you were to fit those parts it will need to be remapped also. As mentioned above Marlow is having this done at the moment to his vagmobile, in fact we are doing the work!

If I was you I'd have a remap done first and go from there before I started throwing parts at it

keithclancy

Waste of money, sell it and buy a larger TDI.

vectra

Gary ITR wrote: »

If I was you I'd have a remap done first and go from there before I started throwing parts at it

Waste of money for the gains, He wants more. Change of engine then remap is a better job

Chimaera

There were two versions of the TDI 90 fitted to the Passat: engine codes AHU and AHH. If you have an AHU, fitting the turbo from a 110 bhp engine will not be trivial. The AHU uses a wastegate turbo which is pressure actuated while the 110 (any version of it) uses a VG turbo which is vacuum actuated.

To fit one of those to an AHU you'll need to upgrade the vacuum system too, as well as change the N75 valve and possibly even the ECU hardware. At the very least an ECU remap will be needed and the car won't be drivable until this is done.

Quick potted history of the TDI lineup in the 3B Passat pre-facelift: there were 6 1.9 engines fitted, 2 each of 90(AHU/AHH), 110(AFN/AVG) and 115bhp(AJM/ATJ). The 90 and 110 engines used the VE injection system and the 115s were PD. All bar the AHU used variable geometry turbos. Turbo interchangability has little or nothing to do with the injection system used - it's all down to the control system for the turbo. Once the car had a variable geometry turbo to start with, a VG turbo will work on it with little modification.

That out of the way, nozzles and remap will get you a good bit. I've got upgraded nozzles and a remap on my 1999 Passat TDI 90 (AHU engine) and according to the dyno it's putting out 138 bhp and 328 Nm of torque. Nozzles are a bit of a minefield though. Fratelli Bosio nozzles used to be the darling of the TDI tuning community but apparently their quality has nose-dived recently. I've been using their PP520 nozzles on my car, but a recent test of the injection system on my car shows them to be worn past spec after 90000 km. I got my remap done at Chipped Ireland (www.chippedire.com). Joe there knows his stuff.

The increasing problem for VE nozzle upgrades is the fact that this injection system is really old technology by now and even getting original parts is becoming a little difficult and upgrade parts are not so common. It's a little easier to get stuff from the US as they had the VE engines up until 2004 and TDI tuning is a significant niche within the VW community there.

Nozzles from a 110bhp TDI won't make a huge difference to your car. Nozzles from the 2.5 5cyl TDI in the Transporter will get you a bigger gain. There were a few different types fitted over the years though: later models got a smaller nozzle with a different injector body and you probably don't want these. There's a good summary of nozzle info at http://www.myturbodiesel.com/1000q/multi/TDI-nozzle-FAQ.htm

Bosch nozzles are the best bet as these would be the OE manufacturer for VW. If you have the part number of the nozzle you want, any Bosch dealer here should be able to get them for you. In the US tuning community, 'Titan' nozzles seem to be gaining some favour - rumour has it these are a Bosch design manufactured under licence by one of the other big DFIE manufacturers. Only supplier I'm aware of for these is www.boraparts.com which is a US based company.

Sorry for the long post, but it's not such a trivial matter to do this properly. Oh and start budgeting for a new clutch and flywheel too. Think about an upgrade clutch if you go for serious mods (http://www.sachsperformance.com/Sachs-Performance-Clutch-Powerclutch/VW/VW-Passat-3B2-08-96-11-00:::2_6_312.html).