AHU tuning

[rich.h44]

Iv been doing a lot of searching on Tuning the AHU and I have a few questions!
Can the 0.216 injectors but put straight in and run the car with out mapping it a month or 2?
Is the pd130 turbo a straight bolt on?
And would an n75 from the 110 or another model help give me more boost before mapping?
Any other pointers would be great to see more power!

Rich

 

[Pimped up vario]

0.184um to 0.216um is a fair jump. Might be a bit sooty. I had this thought myself. I am going with the old bosch 0.205 nossles from my leon and push the turbo as far as it will go and try not to exceed 750 deg celcius egt. 0.216 nossles took my 110 bhp leon up about 15 bhp with out any mapping. Your nossles are 0.184um but I don't know if it works that way. You will need an afn engine code exhaust manifold to be able to run a vnt turbo there is a good conversion thread on tdi club forum. I could be wrong though on that point mrannick is running a gt2260v turbo in a ahu cordy and I'm asking him about that cos there are some turbos that won't fit cos of the rear right engine mount. A pd130 intake manifold gives better flow into engine. Fmic and you can mist it as well. You can take the ecu apart and wire in a 3 bar map sensor. Don't know about the n75s. Did you see that thread that seatmann posted with the hungarian motor in it? Nice.

 

[Seatmann]

Get as big nozzles as you want, don't waste your time with little piddly ones. I'm running fairly big ones that can handle 200bhp but I don't have any mapping and no smoke. You still get a good boost in power.

As for turbo yeh, you'll need a different exhaust manifold but also the ecu can't control it as standard due to it being a vnt type turbo and yours being a waste gate type. You could fit the AFN ecu though most likely if you can find one from the same sort of car. It needs to match up for the sensors or it wont work.

Anyway I got the Bosio power plus 764's from here

http://www.dbwllc.net/nozzle-guides/ve-nozzle-guide/

I got him to set them up for the stock map too and later I can send them back to get re done to flow more fuel if I need to.

The 216's should be not bad though and as long as you get them at least pop tested you should be able to turn the fuel down enough. I know they can at least handle 150bhp. You could try Darkside developments

http://www.darksidedevelopments.co.uk/

or united diesel for setting them up.

http://www.uniteddiesel.co.uk/


Don't go buying rubbish off ebay either without a thorough bit of research as there's lots of fakes around and they can ruin your engine.

And finally yeh, check out tdiclub.com for loads of info including a wastegate to vnt conversion on the turbo.

 

[mrannikk0]

I could be wrong though on that point mrannick is running a gt2260v turbo in a ahu cordy and I'm asking him about that cos there are some turbos that won't fit cos of the rear right engine mount. A pd130 intake manifold gives better flow into engine.

Yes! It dosen't fit like bolt on. In my Vario it has modified to fit standard exhaust manifold. I just recommending to use AGR or SDI intake manifold. (much better flow and quality than AHU) Or PD intake.

 

[rich.h44]

0.184um to 0.216um is a fair jump. Might be a bit sooty. I had this thought myself. I am going with the old bosch 0.205 nossles from my leon and push the turbo as far as it will go and try not to exceed 750 deg celcius egt. 0.216 nossles took my 110 bhp leon up about 15 bhp with out any mapping. Your nossles are 0.184um but I don't know if it works that way. You will need an afn engine code exhaust manifold to be able to run a vnt turbo there is a good conversion thread on tdi club forum. I could be wrong though on that point mrannick is running a gt2260v turbo in a ahu cordy and I'm asking him about that cos there are some turbos that won't fit cos of the rear right engine mount. A pd130 intake manifold gives better flow into engine. Fmic and you can mist it as well. You can take the ecu apart and wire in a 3 bar map sensor. Don't know about the n75s. Did you see that thread that seatmann posted with the hungarian motor in it? Nice.

thanks for that, have you got a link to the vnt conversion thread? i carnt seem to work my way around that forum i just get lost lol, and have you any more info on the 3bar map sensor? and what does it do? not seen the thread that seatmann posted ill have a look for it

 

[rich.h44]

Get as big nozzles as you want, don't waste your time with little piddly ones. I'm running fairly big ones that can handle 200bhp but I don't have any mapping and no smoke. You still get a good boost in power.

As for turbo yeh, you'll need a different exhaust manifold but also the ecu can't control it as standard due to it being a vnt type turbo and yours being a waste gate type. You could fit the AFN ecu though most likely if you can find one from the same sort of car. It needs to match up for the sensors or it wont work.

Anyway I got the Bosio power plus 764's from here

http://www.dbwllc.net/nozzle-guides/ve-nozzle-guide/

I got him to set them up for the stock map too and later I can send them back to get re done to flow more fuel if I need to.

The 216's should be not bad though and as long as you get them at least pop tested you should be able to turn the fuel down enough. I know they can at least handle 150bhp. You could try Darkside developments

http://www.darksidedevelopments.co.uk/

or united diesel for setting them up.

http://www.uniteddiesel.co.uk/


Don't go buying rubbish off ebay either without a thorough bit of research as there's lots of fakes around and they can ruin your engine.

And finally yeh, check out tdiclub.com for loads of info including a wastegate to vnt conversion on the turbo.

awesome stuff, already had a chat to darkside, i just carnt decide who i want to map my car when its ready for mapping?! im stuck between darkside,rstunning, and ******,

i think im pritty set on the 0.216 injectors, im just torn on what turbo to use! what is pop tested?

 

[Pimped up vario]

you can get a three bar map sensor off ebay if it looks cosure, if not grab the part number and get one from tps. I haven't tried it yet myself. I don't know if it fulls the ecu by sending a lower signal but it allows your turbo to boost to 3 bar or 44 psi. Well maybe not quite like that. I had one in my leon and it permitted a higher boost presure. You will need the plug bit to wire into the sensor itself. I got in contact with turbo dynamics today to see how a wastegated hybrid would work out. I will let you know whn they get back to me.

Pop testing is the opening pressure that the injector lets the fuel through the nossle. 220 bar i think. I think I might go straight to 0.226 now. I tried to get mine out, 128000 miles and are stuck solid. I'll let someone else do them incase I break them.

I'm no good at putting in links so here's the title that you want to put in the search in tdi club forum

My AHU Corrado VNT GT1749va Turbo Build Thread

Just like that

 

[rich.h44]

Had a look got the map sensors and I carnt find any with any wires or for the older no pd engines!
Yeah would be good to see what they can do!
Iv started reading through that thread on tdi club! Loads of info and loads of links to help!

 

[Seatmann]

Your map sensor is in your ecu on the AHU/1Z engined cars so don't waste your time looking for a regular upgrade lol. I'll find some links for you later from the tdi club regarding tuning the AHU, you might need to do a bit of tweaking to get a vnt in there but it should fit because the 2000 plate cordy came with the ALH engine which mounted exactly the same way, same engine bay etc but it uses the vnt turbo.

If you're sticking with the .216 nozzles you could stick on a vnt from the likes of the AFN and a map, that would get you to the 150bhp mark with about 300ft/lbs of torque.

http://www.darksidedevelopments.co.uk/caddy-mk2-1-9-8v-tdi-alh/

Or you could go nuts

http://forums.tdiclub.com/showthread.php?t=354947

 

[rich.h44]

Fantastic stuff thanks, ideally I'd like a bolt on turbo so I might just go for the 110 turbo, unless I know for certain what I'm doing putting a vnt on and what I need to do!

 

[Seatmann]

The 110 is a vnt, it's just the AFN is the most similar tdi engine to yours so might be an easier option.

 

[Pimped up vario]

I haven't seen a thread on it or seen it done but heard that you disconnect the wiring in the ecu that sees the transducer/pressure diaphram and put wiring in place to go to the external pressure sensor that you then plumb charge piping not sure if that would be pre or post intercooler.

 

[Seatmann]

I think the guy to maybe ask would be a user called G60ING on the tdi club, I'm sure it's him that's been doing it to his corrado.

 

[Pimped up vario]

That's the one. I haven't got to read it yet. I read yours. Coming along nicely. I like the wee touches like the dials and lecy windows. I'm not too dialled into mfa vdo clock difference yet, I'll have white ones please. Nice wheels. I don't think I would've spent the time on the undertray though but I bet it saved about £100 from the dealers or sourcing one from a breakers and I suppose metal work is good fun esp when you get to beat it with a hammer. I read the hungarian post. His replies to some enquiries are a bit confusing like the answer to head studs. I love to tinker and would like to do an engine build anyway so I didn't like the sound of cams before but mrannick0 made them sound very appealing. A lightened/or balanced engine with ceramic coated pistons and a cam of some sort, arp studs/fastners a big vnt turbo, 12mm pump and 0.232 um nossles and the ecu sorted. And finally the bit that gets me is that 20 psi from a small turbo can be bad for the engine but 20 psi from a big one would be better for it, I always thought that manifold pressure was manifold pressure or is it to do with flow rates and so on. Good stuff I'll be an engine designer one day.

 

[mrannikk0]

Welcome to the DARK side!!
He is gone now!

 

[Seatmann]

@Pimped up Vario

I think you have to watch about getting caught up in the actual nozzle size, mine are .232 but they're only good for around 200bhp or so allegedly. It's more about how much they can flow due to their design.

It's boost spikes, they can be an issue with smaller turbos pushed hard compared to bigger turbos working within the same range.

Regarding a light and balanced engine, good for racing, bad for trying to drive normally on regular roads. Even with a really light flywheel alone you'd have issues with stalling etc.

 

[mrannikk0]

You should start to thinking like Seatmann wrote that where You want to use that all power.

Like my Vario is not a good track car! And I can say that it's not a good car in winter times here! Power comes out so rapid and strong at low rpm. But it's really fun to drive rolling roads in summer time!! However You can modified nature of the engine totally with remapping!

 

[Pimped up vario]

So size doesn't matter? I haven't really looked into it, I was just quessing at 0.232. My car is absolute crap in the snow yet my leon was like a 4 * 4 with a lot more power and they both have the same gearbox, differential and near identical tyres but I'm working on that.

I had a funny feeling that changing the flywheel on a diesel wasn't a good idea. There's a guy on the tdi club forum had a lightened one that caused him a lot of heart ache. But balanced internals would give for smoother engine running (I KNOW IT'S A DIESEL) and raise the rev limit ceiling and give the potential for power to be generated at higher revs.

About 250 bhp sounds nice and drive it like a holigan down the "Autobahn" Hope Ash isn't watching this thread.

What you doing Rich.h44? Turbo dynamics hasn't got back to me, gonna phone them now.

 

[Seatmann]

Different ratios between the vario and leon boxes but yeh, more or less the same. Ash as in Kitt? He's bought my box from my vario for his polo but still to actually collect it or fit it lol.

There's some crackers on tdiclub that rev way up without anything being lightened, way over the red line with amazing poke.

And yeh the nozzles are a funny one, you can have two the exact same size but one could flow at least 50% more than the other due to it's internal design etc.



Hope yir amnesia gets better soon although you wont remember having it

 

[Pimped up vario]

Nigel from turbo dynamics was very helpful and came back to me but said that they don't have enough info to build a wastegated kkk seris hybrid turbo for the AHU engine, I would have to do a bit of research myself. They did reckon that they could do a gt 15 hybrid though for about £395 when using your orginal unit.

Also found a thread, I'll have to figure out how to link them, by cbjetta where he uses a turbo from a CDI 320 merc on an AHU engine, Albeit with some fabricated adapter gaskets/flanges.

Nigel threw me a bit by saying that the arl turbo has an intergrated hotside housing and exhaust manifold. I thought that I needed a afn manifold and the arl turbo. I just need the turbo then and manifold is attached. Then make sure that the compressor housing is clocked in the orientation required for best fitment.

Ash as in Bashie. He's an insurnace sales man. I was having a wee joke with him about declaring mods done on his car.