200HP 1997 Jetta TDI

VW97JettaTDI

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Aug 10, 2008
Location
Wisconsin
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VW97JettaTDI
Ok so here is whats going down.
~Heavy duty high performance pistons and rings with entrance and exit hole in piston for cooling.
~Bigger injectors (.205).
~K03/K04 Turbo direct swap of stock K03
~Exhaust Dump Pipe
~11mm Fuel pump
~FMIC
~Cut off EGR
~Bigger Clutch
~ AND FINALLY dyno tuned to incorporate it all!

I have several companies i can buy from and some parts purchased, but i would like so input. All comments are welcome, im looking to sort out the flaws in the build before i make the final cuts.

More importantly, what would u do diff. and where would u get it from?
Thanks iin advance! :)
 

Rub87

Top Post Dawg
Joined
Dec 10, 2006
Location
Belgium
TDI
Ibiza '99 90HP
Definatly not with those nozzles.. I'd go for R520 and 11mm pump.. In holland there is an AGR with around 200hp, has 12mm pump and R520, some airflow mods (intake manifold/exhaust) and a sort of hybrid wastegate turbo of which i don't know the specs
 

TDIMeister

Phd of TDIClub Enthusiast, Moderator at Large
Joined
May 1, 1999
Location
Canada
TDI
TDI
The turbo is also insufficient. The K03 half of the equation is similar to the GT1544S used in the 1Z/AHU engine. Even the K04 compressor will be stretched to support 200 HP.
 

TDIMeister

Phd of TDIClub Enthusiast, Moderator at Large
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Canada
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There are other, I would argue IMO better, options for intakes than even the PD150 units.

As installed in my former car:


Or if for whatever reason you're not comfortable with a plastic manifold:


But I would recommend this after the injectors, pump, turbo (and not to forget exhaust) and tune are done.
 

mrchill

TDIClub Enthusiast, Super Secret Diesel Ninja Vend
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96 B4v red \ 98 Mk3 green\98 Mk3 Jetta black\ 99 Mk4 Jetta green x2\ 99 Mk4 Golf silver x2\ 99 Mk4 Jetta black\ 97 B4 sedan green\04 JSW gold\03 JSW silver
You need a lot more turbo, a serious tune(vnt conversion is the easiest way to power) and lots more intake and a good intercooler. As was said, the nozzles are not near enough either. I would consider a port job on the head as well. If you are doing modded pistons...this is probably a given anyway.
 

dieseleux

Théoricien -TDIClub Contributor
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Pas assez loin pour vider ma tank!
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Jetta TDI 02
K03/K04 hybride limit power to 120 wheel hp!
Turbine are too small for more power, i have this turbo in my car and is never put more than 121whp with my Gtech RR.




Dieseleux
 

kepsu

Active member
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Sep 13, 2008
Location
finland
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golf III tdi
Dieseleux, is your turbine the original turbine from a k03.? I have a k03/04 hybrid that has bigger turbine and also bigger compressor wheel. Should be enough for about 160 at flywheel. I don't know what is makes in whp...
 

dieseleux

Théoricien -TDIClub Contributor
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Pas assez loin pour vider ma tank!
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kepsu said:
Dieseleux, is your turbine the original turbine from a k03.? I have a k03/04 hybrid that has bigger turbine and also bigger compressor wheel. Should be enough for about 160 at flywheel. I don't know what is makes in whp...
My Hybride have K03 turbine yes, with K04 on compressor side, spool at 2000-2100rpm compare to original K03 spool at 1800rpm.
121whp is aprox 140hp at engine.



Dieseleux
 

Stealth TDI

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Joined
Feb 13, 1998
Location
Newport News, VA
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2017 GTI APR Stage 3 (395 hp/376 lb-ft)
Hello,

I dyno'd at 136-whp and 263-lb/ft with RC3, a K03/K04, and PP502s on a Dynapack. AThreeTDI dyno'd at 149-whp and 302-lb/ft with an Alligator tune similar to RC3, a K03/K04, and PP764s. I'm not sure of the dyno; but I'm sure it was a roller type.

I'm going to try going back to the dyno this fall with my PP502s, RC6, a lift pump, water injection, a PD130 intake manifold, and a new K03/K04 hybrid. I think I was beyond 140-whp at this spring's drag day. I hope to be close to 150-whp with the setup I've just listed. Time will tell. ;)

Something to keep in mind: It's easy to feel let down when seeing the ALH's making 200-whp and we AHU folks are sucking wind. But remember that we have a 500-lb weight advantage over the A4/A5s. It tends to nearly equalize the overall power to weight ratio.

Good Luck,

Scott
 

dieseleux

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Stealth TDI said:
Hello,

I dyno'd at 136-whp and 263-lb/ft with RC3, a K03/K04, and PP502s on a Dynapack. AThreeTDI dyno'd at 149-whp and 302-lb/ft with an Alligator tune similar to RC3, a K03/K04, and PP764s. I'm not sure of the dyno; but I'm sure it was a roller type.

I'm going to try going back to the dyno this fall with my PP502s, RC6, a lift pump, water injection, a PD130 intake manifold, and a new K03/K04 hybrid. I think I was beyond 140-whp at this spring's drag day. I hope to be close to 150-whp with the setup I've just listed. Time will tell. ;)

Something to keep in mind: It's easy to feel let down when seeing the ALH's making 200-whp and we AHU folks are sucking wind. But remember that we have a 500-lb weight advantage over the A4/A5s. It tends to nearly equalize the overall power to weight ratio.

Good Luck,

Scott

Why new K03/K04 hybride?
And yes, i suppose AHU head are less flow than ALH head...

Dieseleux
 

12MPGHWY

Veteran Member
Joined
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Location
el California
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none
I have a 98 A3 with an AHU I am shooting for 180 WHP, so far I have obtained

An 11mm ALH pump
A PD 130 intake manifold
A PD 130 3 bolt 2 piece exhaust manifold
Sprint 764 nozzles

Looking at getting a jeep liberty 2056V to mostly complete the package.
 

Rub87

Top Post Dawg
Joined
Dec 10, 2006
Location
Belgium
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Ibiza '99 90HP
dieseleux said:
Why new K03/K04 hybride?
And yes, i suppose AHU head are less flow than ALH head...

Dieseleux
If it has 7mm stem and ports are perfect clean it actually flow quite good with stock cam, I already made 170ish with a gt1749v and minor smoke on good diesel, 1.25 bar at 4000rpm, engine had +500.000kms.., ported intake manifold, R520 nozzles, AFN injection pump, engine is now still running and approaching 570.000km, still going strong, it's al in the maintenace ;)



on the other hand I had PD150 engine that didn't made 190hp with 1.5bar at 4000rpm, probaly because clogged intake ports/manifold due egr
 

Rub87

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Joined
Dec 10, 2006
Location
Belgium
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Ibiza '99 90HP
Why don't you guys source a passat/A4 gt1749VA and manifold, it spools at 1400rpm and flows 170hp at least in a well maintained enigne, smokefree.. you only need downpipe (you'd need one anyways) and a N75 vavle and a tune (which you'd need anyways) and atleast alh style intakemanifold preferable PD130 style..
 

traxterXT

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Ottawa On, Canada
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jetta 2005
Keep the GT series in that car dont try to mess up with a VNT in an a3. to make 200whp a garrett GT2056, R520 injectors machined pistons and 30PSI should be good to make 200Whp all day long. My friend Dynoed 190hp at 25PSI with that setup and an evrymod over a stock ECU. you need a MK2 TD intake and exaust manifold, the turbo housing need to be re-oriented and an adapter plate done for the GT20 turbo. for the fact of GT being better Audi r10 and R15 are running Garrett GT series turbo because the can handle more stress and heat.
 

TDIMeister

Phd of TDIClub Enthusiast, Moderator at Large
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Listen people, if you are shooting for big HP numbers, regardless 1Z/AHU/ALH/AHF/etc., you're not going to do it with anything less than Race520 injectors and a GT20xx-series or bigger turbo. It's as simple as that. You'd think that 12 years after it was first done people would have figured that out already.
 

RomSL

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Feb 8, 2008
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Philly
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Porsche Cayenne
Rub87 said:
Why don't you guys source a passat/A4 gt1749VA and manifold, it spools at 1400rpm and flows 170hp at least in a well maintained enigne, smokefree.. you only need downpipe (you'd need one anyways) and a N75 vavle and a tune (which you'd need anyways) and atleast alh style intakemanifold preferable PD130 style..

Rub, will this turbo fit my AGR manifold? I know, I probably asked you thousand times already, I just can't make up my mind. I need smth reliable to fit PP502 and this "smth" hasn't to be unique, hard-to-find-turbo in case somethind bad happens to it. We have plenty Passats/Superbs PD130 in the area, way fewer Golf/Seat PD130 and non cars with PD150 engines, so the turbo will be definitely used from one of the mentioned above cars.
 
Last edited:

Rub87

Top Post Dawg
Joined
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Belgium
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Ibiza '99 90HP
it could maybe be made to work, I've never tried this option because over here there are afn/asv manifolds enough :D

here's a video of the car with gt1749v, it's a cordoba, weight is probaly around the same as the jettas mk3 you have over there

http://www.youtube.com/watch?v=8_fPvyBMGfk

it doesn't have 200hp, maybe 170, but the car was so pleasant to drive, instant torque, even at 1500rpm, it was faster than octavia rs 20vt's, also faster than a mini cooper S in highway sprints.. the total cost of the car was less than 1000€
 

RomSL

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isn't gt1749v the same as VNT15?
VA - PD130
VB - PD150
VC - BKD 2.0TDI
 

Rub87

Top Post Dawg
Joined
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Location
Belgium
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Ibiza '99 90HP
yes, approx the same as a vnt15, only has better vane ring.. you recognize the difference at the actuator dashpot, the vnt15 has a small diameter pot while the gt1749v have the normal actuator, same as va and vb etc..
 

hatemi

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VC isnt from BKD but from the 170hp 2l engine.

I wouldnt use a wastegate P&P hybrid. They just arent that good. Finturbo has made alot of those and depending on the wheels and housings used they are good for 160-200hp, but the spool isnt that good. Pretty much stoc power till 2000rpm.

I know that a smokey 230hp can be had with this setup from AHU:
GT22V from Transporter 151hp in stock AHU manifold with adapterplate
2.5" pipe
large IC
12mm pump
DSS Ultime nozzles
Stock intake and aircleaners etc.

If you are willing to fabricate then your options are endless. And the cost isnt that high. If you want everything Plug and Pray then you are screwed ;)
 

turbo johan

Veteran Member
Joined
Feb 19, 2006
I did a AGR 90 hp with FINturbo pnp turbo (GT2052)
I made over 200 hp but first 2 gears didn't built any boost before 3000 rpm.
In 4th and 5th it spools from 2000 rpm.
It is a nice pnp turbo, but convert to vnt is better.
Better trottle response and better spool in low gears.
I did a lot of AHU's/AGR's with GT1749V(A) conversions.
Runs really nice.

Making relayable 200 hp out of stock AHU is hard.
180 hp is good to do and cost a lot less and lot more relayable.
But please just take R520 nozzles in stead of .205, there way to small.

Johan
 

D_Bat

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Location
Melbourne, Fl.
TDI
1998 Jetta TDI
I just picked up a 2056 for my MK3 TDI. Hoping the 3" exhaust, intercooler, lift pump, PP764, PD150 intake, and re-tune will get me to around 170whp. That's probably pushing the stock 10mm pump. Main goal is between 180-200whp so if I stumble upon a bigger pump or the materials to mod my pump to be bigger for a decent price 200-400 dollars then I'll do that too.
 

numbnuts

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sunny brum uk
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D_Bat said:
I just picked up a 2056 for my MK3 TDI. Hoping the 3" exhaust, intercooler, lift pump, PP764, PD150 intake, and re-tune will get me to around 170whp. That's probably pushing the stock 10mm pump. Main goal is between 180-200whp so if I stumble upon a bigger pump or the materials to mod my pump to be bigger for a decent price 200-400 dollars then I'll do that too.
I would be interested to see how will this spools up, incase my hybrid lets go at some point:cool: Was the 2056 standard fit on anything?
 

D_Bat

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1998 Jetta TDI
They come on a lot of cars. I've got two in the mail. One from a Jeep Liberty and one from a Mercedes. I'm going to be using the Mercedes one for my car since it made 216hp stock and the Jeep one produces 170hp stock. I don't know the differences between the two since I can't find the specific specs on each one but I'm assuming there are slight differences in induces sizes or housings.
 
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