How far can stock internals be pushed on mk4 bew?

[Lewis98]

Hey guys, newbie here, I bought me jetta little over a year ago and love this thing!!!!! the mpgs are great and I am starting to dip in to the thirst for more power, was tossing around the idea of get a GTB 2260 vk turbo but I think it might be to much for stock internals.....????? I will also be upgrading, injectors, intercooler, clutch again probably, and so on. I would love to learn more in any ways that I can All my buddys also have mk4 ALH's so any info on modding those would be great too. Will is hold up? 35psi of boost and close to 300bhp????

 

[InfoSec]

Anything over a GTB1756vk, or about 200hp would require (in order to sleep at night), rods and ARP Head Studs. There are many threads about this on this site, so I say check them out, go with a good tune, because many problems can be eliminated with a tune that doesn't bring on too much pressure too quickly. My car's tune/mods works great. At about 210hp, 370tq, it's hard to keep the wheels from spinning.

 

[Lewis98]

Alright I'll do some more looking. I am planing in apr head studs, just don't really want to do any internals at this time so you would say gtb 2260 what be a bit to much???? Also any recommendations on FMIC's or SMIC's?? was looking at getting Fraid 80%'s or the 783 pd race nozzles. opions???

 

[InfoSec]

Alright I'll do some more looking. I am planing in apr head studs, just don't really want to do any internals at this time so you would say gtb 2260 what be a bit to much???? Also any recommendations on FMIC's or SMIC's?? was looking at getting Fraid 80%'s or the 783 pd race nozzles. opions???

Bosio Race 520's, balanced and pop-tested, with an 11mm pump, large smic, with a 1756 and a tune would get you around 200hp and about 350+tq... way better ride, spools nicely, and is a complete blast to drive... on stock internals. Malone stage 5 is what I have and it works very well. You can buy almost all of the parts you need from RyanP at Darkside. I bought my smic from Rodriguez. Lots of people have different stories/opinions, so I would definitely read as much as you can in order to make an informed decision. I would also contact RyanP and others to talk about what you can do w/out changing stock internals... My comments are my own opinions based on just my experience. Good luck!!

FYI, if you were close to Michigan, I'd let you take my car for a spin to see if you like my set-up. Plus it's for sale... (shameless plug!)

 

[Yourbuddysatin]

It’s a PD not an ALH....

 

[InfoSec]

It’s a PD not an ALH....

No kidding. Just giving my 2cents. BEW's are a bit more robust, but I've never seen a crank in an ALH give-way. Rods are pretty damn strong until they hit 215hp. BEW's, probably a bit more. But it all depends on the tune.

 

[InfoSec]

With that said, I'm not sure the 520's will fit a BEW, but these will...

https://www.darksidedevelopments.co.uk/products/firad-80-120-injector-nozzles-for-1-9-2-0-8v-pd-engines.html

 

[Yourbuddysatin]

Lewis98, just contact a tuner and do what they recommend. tunemyeuro, kermatdi, rocketchip, darkside are all good tuners that won’t steer you wrong. Tell them the HP goal and they will tell what to do and not to do.

 

[InfoSec]

Sorry, I came across a bit crass. Not my intension.

 

[InfoSec]

Jeff from rocketchip should be at the fall GTG at Kirk's (RS90Kirk) house in a few months.

 

[Yourbuddysatin]

Another dead thread.....

 

[bhodgkiss]

If mapped well a PD will do 300bhp
But I'd just push to more like 270bhp and know its gonna last

 

[Lewis98]

Alright I guess the next step for me is getting a hold of a tuner. I alright have an idea for what I am going to throw at it for parts. Gtb 2260vk turbo, on stock manifold, head studs, maybe a new intake,???? stage 4 clutch, was looking at firad 80% injector nozzles ( or injector swap at darkside), stage 3 colt cam, and inter cooler probably front mount, an upgraded map sensor bar 3 or 4. I will probably end up getting tuned by malone.

 

[Lewis98]

already have 3 in straight pipe turbo back exhaust

 

[Yourbuddysatin]

I think you will need a bhw exhaust manifold. Get a pd150 intake manifold also.

 

[F1 tuning]

off topic, anyone have exhaust manifold for BRM to allow bolt on GT2256V
thanks

pm for info

 

[Nevada_TDI]

A BEW with just a tune is a blast to drive. I don't remember the specifics torque and horsepower, but since a b e w already has larger injectors and turbo on it than an alh you might just be happy there. start in expensive and then work your way up.

 

[Lewis98]

OK notes taken!!!

 

[Lewis98]

I already have a 2 stage tune, and its alright but I want more haha

 

[Yourbuddysatin]

I’d contact darkside. They are pretty well rounded with the ALH and PD cars.

 

[Curious Chris]

I would get a Limited Slip Differential. As you go up on power the 1 wheel drive slips a lot. I have a Wavetrac and love it. If I had known how nice it would be I would have put that on before my big FMIC.

 

[Lewis98]

Alright I contacted darkside they gave me a list of parts, for the build and recommendations, they said stock internals would hold to 260-280bhp

 

[Yourbuddysatin]

When I contacted them for my alh they actually told me it would be better to start with a bew bottom end since they are stronger than alh. Good guys there.

 

[Lewis98]

Yeah they said after that if i wanted 300+ to go with a 2.0tdi bottom. Yeah they were really helpful with a parts list.

 

[coalminer16]

What is the list/cost?

Sent from my SM-G950U using Tapatalk

 

[Yourbuddysatin]

What is the list/cost?

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To go to a 2.0L?

 

[Lewis98]

Please see the list of parts below:

Engine:
GTB2260VK Turbo Kit with Tubular Stainless Manifold and 3" Downpipe - £2100 - http://www.darksidedevelopments.co.uk/products/darkside-gtb-turbo-kit-for-1-9-8v-tdi-engines.html
Race Injectors - £600 (Modifying your injectors) - http://www.darksidedevelopments.co....-8v-tdi-with-firad-50-80-120-160-nozzles.html
Injector Bolts - £65 - http://www.darksidedevelopments.co....-bolt-kits-for-1-9-2-0-8v-tdi-pd-engines.html
Intercooler - £400 - http://www.darksidedevelopments.co....tercooler-kit-fmic-for-1-9-tdi-pd130-asz.html
(Euro Crash Bar (Needed for Intercooler) - £50)
Alloy Radiator - £175 - https://www.darksidedevelopments.co...diator-for-vw-golf-mk4-platform-vehicles.html
Lower Temp Thermostat - £27.50 - https://www.darksidedevelopments.co...oolant-thermostat-for-1-9-8v-tdi-engines.html
Custom Inlet Manifold - £200 - http://www.darksidedevelopments.co....ustom-aluminum-1-9-tdi-8v-inlet-manifold.html
EGR Cooler Delete - £20 - http://www.darksidedevelopments.co....-us-alh-bew-pd100-egr-cooler-delete-pipe.html
4 BAR MAP Sensor - £35 - https://www.darksidedevelopments.co...p-manifold-pressure-sensor-0-281-006-059.html
Rocker Gasket - £12.50 - http://www.darksidedevelopments.co....ver-gasket-for-1-9-2-0-tdi-8v-pd-engines.html

These are the parts we can supply 'off the shelf'. Personally I would recommend a Single Pass setup, as large as possible with custom pipework. The Battery will need to go in the boot, and stock Air Box has to go.

Race Camshaft - £700 - http://www.darksidedevelopments.co....e-camshaft-kit-for-1-9-2-0-8v-pd-engines.html
Cam Cap Bolts - £20 - http://www.darksidedevelopments.co.uk/products/cam-cap-bolt-kit-for-1-9-2-0-8v-tdi-pd-engines.html

To get 300bhp+, you need a Ported Head and the GTD2872VK instead of the GTB2260VK. 120% Injectors would also be required.

Keeping everything safe, the Full Engine would need to be build. I would do it around a 2.0 Bottom End

Engine Build
Upgraded Valves - £340 - http://www.darksidedevelopments.co....ust-valves-for-1-9-2-0-tdi-8v-pd-engines.html
Valve Springs - £180 - http://www.darksidedevelopments.co....-retainers-for-1-9-2-0-tdi-8v-pd-engines.html
Ported Head and Assembly - £1300 - https://www.darksidedevelopments.co.uk/products/darkside-1-9-tdi-8v-pd-ported-head.html
Head Stud Kit - http://www.darksidedevelopments.co.uk/products/head-studs-for-vw-1-9-2-0-8v-tdi-pd-engines.html - £225
Head Gasket - http://www.darksidedevelopments.co....head-gasket-for-1-9-tdi-with-bhw-pistons.html - £40 - For this, you need to know the Piston Protrusion, so the bottom end will need to be assembled first to check 100%. 2 Hole is usually the right thickness
Head Set - £30 - http://www.darksidedevelopments.co.uk/products/head-set-for-1-9-tdi-8v-engines-mk4-platform.html
Pistons and rings - http://www.darksidedevelopments.co.uk/products/vw-2-0-bhw-pistons-for-1-9-8v-tdi.html - £500
Rosten Rods - http://www.darksidedevelopments.co....-for-1-9-pd130-pd150-2-0-tdi-pd140-pd170.html - £400
ARP Mains Studs - http://www.darksidedevelopments.co....ains-cap-stud-kit-for-all-vw-tdi-engines.html - £120
Crank Bearings - http://www.darksidedevelopments.co.uk/products/vw-1-9-2-0-tdi-complete-crankshaft-bearing-kit.html - £40
Rod Bearings - http://www.darksidedevelopments.co....lete-rod-bearing-kit-sputter-bearing-kit.html - £75
Thrust Bearings - http://www.darksidedevelopments.co.uk/products/1-9-2-0-tdi-complete-thrust-bearing-kit.html - £15
Rear Main Seal - http://www.darksidedevelopments.co....eal-for-1-9-8v-tdi-engines-06a-103-171-a.html - £40

Transmission - I would upgrade to a 6 Speed for sure. Usual prices are here

http://forums.tdiclub.com/showthread.php?t=373687

5 to 6 Speed Swap - £1250 GBP
Darkside HD SMF, Clutch Kit and Releaser - £700 extra - http://www.darksidedevelopments.co....ywheel-smf-clutch-kit-for-vw-02m-6-speed.html
LSD Installation including ARP Bolts, New Diff Bearings and Upgraded forks - £900 GBP extra - http://www.darksidedevelopments.co.uk/products/quaife-02m-2wd-atb-helical-limited-slip-diff-lsd.html

Hope this helps and gives and idea on costs.

This is what they gave me for a parts list.

 

[Yourbuddysatin]

That’s about the same as what they gave me for my ALH. I have around $6k between the engine build and turbo set up. It’s a steep hill to go down....

 

[Lewis98]

Yeah that is very true, but i've been doing some shopping and have found different places to get the same part @ way lower prices.

 

[Yourbuddysatin]

I found it was easier to just get it all from them myself. One stop shop and ship it all over one time. Some things I did have to source from the US but most I got from darkside.