MK4 4motion ATD > ASZ or ARL

Hello
I have a Mk4 TDI 4motion 101HP

i have plans to buy an ASZ or ARL engine (130hp resp 150hp)
My goals are to hit about 200HP stable.
i have tried to google about this with no luck about these questions

*do i need to have the whole ECU that comes with the engine or does it work with my current ECU (only Mapping needed)

* how much horsepower/Nm does the 02M gearbox endure

* my goal is to buy an ASZ or ARL engine and do upgrades of different moving parts, and tips on what items to upgrade to hit stable 200 hk
`
* Have anyone done this before ? and have some tips for me ?


Thankful for every answer
kind regards
kevin

tehreal said:

Hello
I have a Mk4 TDI 4motion 101HP
i have plans to buy an ASZ or ARL engine (130hp resp 150hp)
My goals are to hit about 200HP stable.
i have tried to google about this with no luck about these questions
*do i need to have the whole ECU that comes with the engine or does it work with my current ECU (only Mapping needed)
* how much horsepower/Nm does the 02M gearbox endure
* my goal is to buy an ASZ or ARL engine and do upgrades of different moving parts, and tips on what items to upgrade to hit stable 200 hk
`
* Have anyone done this before ? and have some tips for me ?
Thankful for every answer
kind regards
kevin

Click to expand...

Very easy to get 200hp from ASZ or ARL.

Both can be used with your current ECU and wiring harness, no changes needed. I would suggest ASZ as they are more common and pretty much the same as the PD150.

For 200+ hp, PD150 turbo (GT1749VB) can hit around 195-200, but really a hybrid turbo, or gt1752 would suit your needs better.

02m gearbox you will have no issues with 200hp, maybe just put a new clutch or a single mass setup (both will probably be fine around 200hp)

Best upgrades to make for around 200hp will be bigger downpipe / decat / sports cat and exhaust, bigger intercooler setup and then a new turbocharger (there are many different turbo suitable for 200-230hp)

jwrb said:

Very easy to get 200hp from ASZ or ARL.
Both can be used with your current ECU and wiring harness, no changes needed. I would suggest ASZ as they are more common and pretty much the same as the PD150.
For 200+ hp, PD150 turbo (GT1749VB) can hit around 195-200, but really a hybrid turbo, or gt1752 would suit your needs better.
02m gearbox you will have no issues with 200hp, maybe just put a new clutch or a single mass setup (both will probably be fine around 200hp)
Best upgrades to make for around 200hp will be bigger downpipe / decat / sports cat and exhaust, bigger intercooler setup and then a new turbocharger (there are many different turbo suitable for 200-230hp)

Click to expand...

Thanks for the response, maybe now i can start the project.
What good upgrades are easy to do when the engine is out ? and where can i buy them (rod bearings if needed etc..)

kind regards

I'm not sure if you got started on your project yet, but here are few easy things you can do if you're looking for some extra power out of your new engine.

1. Upgrade the nozzles on your injectors to =80% Firad nozzles. https://www.uniteddieselshop.co.uk/vag-19lt-tdi-pd-high-flow-injectors-set-of-4-injectors-252-p.asp

2. Go with a bigger GTB series turbo. Such as these.
https://pioneering-performance.com/collections/uprated-turbos/products/gtb2260vk-plug-n-play-for-1-9-arl-asz-alh-including-custom-cast-manifold
https://pioneering-performance.com/collections/uprated-turbos/products/gtb2260vk-plug-n-play-for-1-9-arl-asz-alh-including-custom-cast-manifold-lightweight-billet
For better response you could go with either a GTB2060VKLR or a
GTB2260VKLR

Here are 2 other places that you could get a GTB turbo from.
https://gottuned.com/big-turbo-upgrade-for-vag-diesel-engine-tdi-cheatsheet/
http://www.turbo-upgrade.com/categorii/gtb2260vk/103/

Just make sure you install a set of ARP head studs before you crank up the boost with one of those GTB turbos or you could risk lifting the head.
http://rosten-performance.com/products/engine-parts-diesel/bolts-and-studs-engineparts-diesel/headboltsstuds-bolts-and-studs-engineparts-diesel/1-9-2-0-tdi-pd-8v-arp-stud-set-cylinderhead/

If you end up wanting more power, there's plenty more you can do to these engines to get them close to if not over 300hp.
Good luck with your swap/build.

Also don't forget PD150 headbolts.

3L3M3NT said:

I'm not sure if you got started on your project yet, but here are few easy things you can do if you're looking for some extra power out of your new engine.
1. Upgrade the nozzles on your injectors to =80% Firad nozzles. https://www.uniteddieselshop.co.uk/vag-19lt-tdi-pd-high-flow-injectors-set-of-4-injectors-252-p.asp
2. Go with a bigger GTB series turbo. Such as these.
https://pioneering-performance.com/collections/uprated-turbos/products/gtb2260vk-plug-n-play-for-1-9-arl-asz-alh-including-custom-cast-manifold
https://pioneering-performance.com/collections/uprated-turbos/products/gtb2260vk-plug-n-play-for-1-9-arl-asz-alh-including-custom-cast-manifold-lightweight-billet
For better response you could go with either a GTB2060VKLR or a
GTB2260VKLR
Here are 2 other places that you could get a GTB turbo from.
https://gottuned.com/big-turbo-upgrade-for-vag-diesel-engine-tdi-cheatsheet/
http://www.turbo-upgrade.com/categorii/gtb2260vk/103/
Just make sure you install a set of ARP head studs before you crank up the boost with one of those GTB turbos or you could risk lifting the head.
http://rosten-performance.com/products/engine-parts-diesel/bolts-and-studs-engineparts-diesel/headboltsstuds-bolts-and-studs-engineparts-diesel/1-9-2-0-tdi-pd-8v-arp-stud-set-cylinderhead/
If you end up wanting more power, there's plenty more you can do to these engines to get them close to if not over 300hp.
Good luck with your swap/build.

Click to expand...

Good advice. For 200-230hp stock injectors will be more than ok, and will save a lot of money. Nice shout on a GTB2060, great little turbos and will more than cover his power goals.

I reccomended a smaller turbo to help with response a little. A smoke free tune on a 2060 can have a tendency to have quite a bit more lag than a stock 1749VA (on the 130) or VB (on the 150).

Injectors are a must if power will be pushed past 240-250hp, which is the realistic limits of the stock 550cc 130/150 injectors without things becoming melty melty.

ARL 150 12.9 Headbolts are a must though!

mur3633 said:

Also don't forget PD150 headbolts.

Click to expand...

jwrb said:

Good advice. For 200-230hp stock injectors will be more than ok, and will save a lot of money. Nice shout on a GTB2060, great little turbos and will more than cover his power goals.
I reccomended a smaller turbo to help with response a little. A smoke free tune on a 2060 can have a tendency to have quite a bit more lag than a stock 1749VA (on the 130) or VB (on the 150).
Injectors are a must if power will be pushed past 240-250hp, which is the realistic limits of the stock 550cc 130/150 injectors without things becoming melty melty.
ARL 150 12.9 Headbolts are a must though!

Click to expand...

Depending on which engine he went with he'd already have PD150 headbolts in the ARL he talked about swapping in. That's why I suggested upgrading to a set ARP PD head bolts that you can get at Rosten Performance.
http://rosten-performance.com/products/engine-parts-diesel/bolts-and-studs-engineparts-diesel/headboltsstuds-bolts-and-studs-engineparts-diesel/1-9-2-0-tdi-pd-8v-arp-stud-set-cylinderhead/

I think the GTB2060VKLR with ceramic ball bearings responds better than people give it credit imo. Is it going to spool like the factory gt1749vb, no, but once you spool the GTB2060VKLR at around 2200 rpm or so you have power all the way to redline, where as the factory turbo signs off at about 4250 rpm.

I know if I had the choice 12 years ago to buy a vnt-17/22 or a GTB2060VKLR for $300-400 more I definitely would have gone for the GTB2060VKLR.

If you're already going to have the engine out it's the perfect time to install a slightly larger turbo and injectors to have room to grow with that turbo versus maxing out the factory turbo and injectors to get anything much over 220bhp.