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Go Back   TDIClub Forums > VW TDI Discussion Areas > TDI Power Enhancements

TDI Power Enhancements Discussions about increasing the power of your TDI engine. i.e. chips, injectors, powerboxes, clutches, etc. Handling, suspensions, wheels, type discussion should be put into the "Upgrades (non TDI Engine related)" forum. Non TDI vehicle related postings will be moved or removed. Please note the Performance Disclaimer.

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Old October 15th, 2011, 10:23   #1
struikie
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Join Date: Oct 2007
Location: Netherlands
TDI(s): BMW 335d E91
Default Audi B7 avant 2.0TDI 16V

sold the B5 (225bhp 445Nm) and I am now moving on with a 2005 B7 avant...
it's a Pro-line which means it has a lot of gadgets and the leather-alcantara sport interior...






fitted a FMIC today in preparation for the GTB2056VK that is going on next tuesday...
ordered an adapterplate from Ryan and a BMC CDA filter to replace the stock airbox as the actuator sits where the airbox normally goes
the GTB2056VK was fitted to the B5 bij turbo_johan who has converted it to vacuum...





the 63mm stainless downpipe turbo_johan made for the B5 is going on the B7...



also got some stoppingpower...
Porsche Cayenne calipers made by Brembo... these fit inside a 17" wheel and are almost plug&play...
just needs bushes to fit (M16 to M14) and Mercedes C230 Sport 330x28mm discs...






MODIFICATIONS:

Motor:
* diy FMIC met VVT piping
* Garrett GTB2056VZK turbo
* VVT 63mm RVS downpipe
* VVT chip op maat naar 265pk en 500Nm
* 4 bar MAP-sensor
* versterkte koppeling
* Simons 63mm uitlaat met L en R einddemper
* balansassen verwijderd en 1.9olie pomp gemonteerd

Remmen en onderstel:
* Porsche Cayenne klauwen met 330x32mm Volvo V70R schijven monteren met Ferodo DS2500 blokken
* 300x22mm S4 achter remmen met Ferodo blokken
* H&R stabi's - 32mm voor en 24mm achter
* KW streetcomfort schroefset

Interieur:
* ambiente verlichting (met sterkere LEDs)
* set velours vloermatten
* verlicht kaartjesbakje en bekerhouder
* ESP knop, kaartenvakje en bekerhouder met chroom randje
* ramen getint
* DLR schakelaar
* to do: stoelverwarming

Exterieur:
* Waterkast afdekking en RS4 afdekking bestuurderszijde
* Westfalia afneembare trekhaak
* Bi-xenon koplampen
* automatische hoogte regeling gemonteerd
* S-line spoiler
* S-line doorblades
* S-line voorbumper
* S-line achterbumper

Multimedia:
* dubbel din ombouw + Alpine INA-W920R headunit
* Front speakers: Audio System HX165Phase
* Rear speakers: Audio System HX165Phase
* Mosconi ONE 120.4 DSP versterker + Mosconi 60.2 versterker
* custom sub met JL 10W3V3
* kleuren FIS teller
JW
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| 2007 BMW 335d | 3.0 6cil BiT + DPF | 385bhp 740Nm |
| 2009 VW Polo Highline | 1.6 TDI CAYC + DPF | 138bhp 304Nm | SOLD |
| 2005 Audi A4 B7 | 2.0TDI BLB | 245bhp 510Nm | SOLD |
| 1997 Audi A4 B5 | 1.9TDI AHU | 230bhp 430Nm | SOLD |
| 1992 Audi 80 B4 | 2.3e NG | 133bhp 186Nm | SOLD |

Last edited by struikie; September 2nd, 2014 at 14:19.
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Old October 15th, 2011, 10:26   #2
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Too sweet! Wish those were over here, I want one. Nice upgrades.
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Old October 15th, 2011, 18:44   #3
3L3M3NT
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Wow nice project
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Old October 15th, 2011, 21:50   #4
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Very nice car. Please post pics of the engine bay.
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1998 B5 Passat TDI Compound Turbos
2009 JSW Stage 3 196whp so far
DIY injector calibration http://forums.tdiclub.com/showthread.php?t=383324
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Old October 16th, 2011, 02:06   #5
struikie
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Quote:
Originally Posted by JFettig View Post
Very nice car. Please post pics of the engine bay.
this stock:


the airbox will be replaced with the BMC filter and the EGR-cooler removed..
on the drivers-side I will add the RS4 cover...



JW
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| 2007 BMW 335d | 3.0 6cil BiT + DPF | 385bhp 740Nm |
| 2009 VW Polo Highline | 1.6 TDI CAYC + DPF | 138bhp 304Nm | SOLD |
| 2005 Audi A4 B7 | 2.0TDI BLB | 245bhp 510Nm | SOLD |
| 1997 Audi A4 B5 | 1.9TDI AHU | 230bhp 430Nm | SOLD |
| 1992 Audi 80 B4 | 2.3e NG | 133bhp 186Nm | SOLD |
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Old October 17th, 2011, 04:04   #6
Rub87
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Quote:
Originally Posted by struikie View Post
sold the B5 (225bhp 445Nm) and I am now moving on with a 2005 B7 avant...
it's a Pro-line which means it has a lot of gadgets and the leather-alcantara sport interior...






fitted a FMIC today in preparation for the GTB2056VK that is going on next tuesday...
ordered an adapterplate from Ryan and a BMC CDA filter to replace the stock airbox as the actuator sits where the airbox normally goes
the GTB2056VK was fitted to the B5 bij turbo_johan who has converted it to vacuum...





the 63mm stainless downpipe turbo_johan made for the B5 is going on the B7...



also got some stoppingpower...
Porsche Cayenne calipers made by Brembo... these fit inside a 17" wheel and are almost plug&play...
just needs bushes to fit (M16 to M14) and Mercedes C230 Sport 330x28mm discs...




will post the dynosheet after it has been tuned this week...


JW

I have the same brakes on my exeo for over half a year now (1 set of front tyres).. just love them.. mine are 18" version and I use slightly modified RS4 discs =)
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'99 Black Ibiza GT90: 2260v, ARL bottomend, rosten rods 81mm slugs, 17:1 CR, 35/38mm exh/in valves, 02M, 305mm discs with Brembo calipers, OZ Superturismo 16"x7.5J, .............
Dyno'd area, Old VNT20 setup dyno'd 192whp
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Old October 17th, 2011, 09:31   #7
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Any shots of the engine without the cover? I'd be curious to see it all. What engine code is it?
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1998 B5 Passat TDI Compound Turbos
2009 JSW Stage 3 196whp so far
DIY injector calibration http://forums.tdiclub.com/showthread.php?t=383324
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Old October 17th, 2011, 10:47   #8
struikie
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Quote:
Originally Posted by JFettig View Post
Any shots of the engine without the cover? I'd be curious to see it all. What engine code is it?
it's a BLB engine...
I'll take some pics tomorrow night when I am taking everything apart...

JW
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| 2007 BMW 335d | 3.0 6cil BiT + DPF | 385bhp 740Nm |
| 2009 VW Polo Highline | 1.6 TDI CAYC + DPF | 138bhp 304Nm | SOLD |
| 2005 Audi A4 B7 | 2.0TDI BLB | 245bhp 510Nm | SOLD |
| 1997 Audi A4 B5 | 1.9TDI AHU | 230bhp 430Nm | SOLD |
| 1992 Audi 80 B4 | 2.3e NG | 133bhp 186Nm | SOLD |
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Old October 18th, 2011, 14:37   #9
struikie
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removed the stock turbo...





we'll continue tomorrow...

JW
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| 2007 BMW 335d | 3.0 6cil BiT + DPF | 385bhp 740Nm |
| 2009 VW Polo Highline | 1.6 TDI CAYC + DPF | 138bhp 304Nm | SOLD |
| 2005 Audi A4 B7 | 2.0TDI BLB | 245bhp 510Nm | SOLD |
| 1997 Audi A4 B5 | 1.9TDI AHU | 230bhp 430Nm | SOLD |
| 1992 Audi 80 B4 | 2.3e NG | 133bhp 186Nm | SOLD |
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Old October 18th, 2011, 16:51   #10
K.I.T.T.
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Crossflow head?

Ash
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Old October 19th, 2011, 02:17   #11
JST
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Quote:
Originally Posted by K.I.T.T. View Post
Crossflow head?

Ash
Yes, seems like a much nicer setup. Also that turbo is better accessible.

Nice project Struikie! I'm doing a similair project on a Alfa JTD 16v engine...
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Old October 19th, 2011, 03:14   #12
Rub87
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heads are quite prone on these engine.. also I dunno if these already have the updated balance assembly, if not I would retrofit an oldskool oilpump
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'99 Black Ibiza GT90: 2260v, ARL bottomend, rosten rods 81mm slugs, 17:1 CR, 35/38mm exh/in valves, 02M, 305mm discs with Brembo calipers, OZ Superturismo 16"x7.5J, .............
Dyno'd area, Old VNT20 setup dyno'd 192whp
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Old October 19th, 2011, 11:05   #13
mk1-83
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I have seen the car this day at tj.
Nice work jw any updates after I left the shop?
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Old October 19th, 2011, 12:24   #14
struikie
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Quote:
Originally Posted by Rub87 View Post
heads are quite prone on these engine.. also I dunno if these already have the updated balance assembly, if not I would retrofit an oldskool oilpump
yes... I know.. something to really consider doing...

Quote:
Originally Posted by mk1-83 View Post
I have seen the car this day at tj.
Nice work jw any updates after I left the shop?
yes! we got it all finished and chipped...
we made a small run with the car and it runs like crazy !
I left it the car at VVT so Johan can finish the software on the dyno...



completely removed the EGR and EGRcooler setup...



put the GTB2056VK back on... Johan welded an adapterplate on the
manifold and welded the egr-port shut because the bolts were interfering
with the turbo...
re-used a hose from the egr-cooler to connect the breather...


downpipe from the B5 changed to fit the B7


put the downpipe back on...


put the BMC filter on and cleaned thing up...


as Johan is finishing the software tomorrow... no dynosheet yet...
but it is fast.. that's for sure !!!


JW
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| 2007 BMW 335d | 3.0 6cil BiT + DPF | 385bhp 740Nm |
| 2009 VW Polo Highline | 1.6 TDI CAYC + DPF | 138bhp 304Nm | SOLD |
| 2005 Audi A4 B7 | 2.0TDI BLB | 245bhp 510Nm | SOLD |
| 1997 Audi A4 B5 | 1.9TDI AHU | 230bhp 430Nm | SOLD |
| 1992 Audi 80 B4 | 2.3e NG | 133bhp 186Nm | SOLD |
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Old October 20th, 2011, 03:27   #15
struikie
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first messages are nice !
Johan has already seen 250bhp and 490Nm... but this is a tad too much for the stock clutch...
it will probably end up at 240-245bhp and 440-450Nm...

JW
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| 2007 BMW 335d | 3.0 6cil BiT + DPF | 385bhp 740Nm |
| 2009 VW Polo Highline | 1.6 TDI CAYC + DPF | 138bhp 304Nm | SOLD |
| 2005 Audi A4 B7 | 2.0TDI BLB | 245bhp 510Nm | SOLD |
| 1997 Audi A4 B5 | 1.9TDI AHU | 230bhp 430Nm | SOLD |
| 1992 Audi 80 B4 | 2.3e NG | 133bhp 186Nm | SOLD |
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