Questions: Borg Warner BV43 Turbo for AFN TDI 110bhp

[bhodgkiss]

Hi all,

So from reading through the forum, it sounds like the Borg Warner BV43 turbo from a 2.0 TDI 170bhp PD (B6 Passat or A4?) will fit on my in-line AFN TDI 110bhp engine.

I would have to use the manifold off a PD130 Passat.

Is this correct? What part numbers would i need please?

I've seen these numbers:



BV43B-0139/KG5014 1509 01127/03L253019J V255 (one type)
BV43A-0129/KG5014 0103 00300/03L253019M V255 (second type)

Either of these good for me?​

The 'B' version is the common rail and the 'a' version the PD?
The CR has the yellow sticker and PD the blue one?
Are they all the detacheable manifold type, or are some integral manifold? I need the detacheable as the 16v 2.0TDI manifold doesnt fit on my 8v 1.9?​

What is the difference between the PD turbo and the common rail that has replaced it, as apparently the commonrail version doesnt fit my engine? Did they do away with the vacuum actuator or change the oil pipes or something?

Finally, Is the turbo flange to the cat clocked the same, to fit my standard exhaust (the 3 bolts holding the turbo the cat)? Or is this different? (I have a decat pipe but its the same bolt positioning as the standard one, and I want to use this decat pipe and not buy another one)

Is the BV43 any larger externally than my standard GT1749V turbo? It should fit and not foul anything?

Had anyone fitted one of these to an AFN? What other pipework do I need please?

For say 180-200bhp this is the best turbo for me? I can't use a VB turbo on my in line engine or i'd be going for one of those - not 100% sure why - it does have the integral manifold, so would the turbo just be positioned wrongly and foul something if I tried to use the VB?

Any other turbo options for me? Some people have mentioned the Garrett GT1749VM turbo? But would this fit? how does this compare to a VA or VB in the GT1749V range? And what is the VC?

Thanks in advance,

 

[G60ING]

I am very interested by your questions and I can't wait to see the responses. I have one question, the AFN was used in a couple different body styles. What car is your AFN in?

I plan on using an AFN manifold in my Corrado with an AHU with a GT1749VA from a B5.5

 

[Yucca]

You can use your own exhaust manifold, because AFN manifold and PD130 Passat manifold is same.

 

[Rub87]

PD 170hp BV-43 sould be pnp.. CR 170hp has different flange, PM struikie, he's running that turbo on a AHU

 

[bhodgkiss]

thanks for the info guys,

i thought the pd130 manifold was a better flow type than my standard one?

would i benefit from a pd130 inlet and exhaust manifold?

which engines did the BV43 turbo that I need? A BRD engine code 2.0 TDI B6 Audi? Any others?

I'll message struikie,

 

[ArturCosta]

The turbo comes one Audi A4 2.0TDI 170bhp B7 version. Dont know the engine code , but the turbo has a blue sticker and thats the PNP one.
The one with yellow sticker is from the CR and is not PNP.

 

[bhodgkiss]

thanks for the info.
what psi will the BV43 happily run at please?

 

[ArturCosta]

Dont let it go over 1.7bars in a 1.9TDI and you are safe.

 

[Rub87]

depending on the rpm offcourse

 

[ArturCosta]

depending on the rpm offcourse

Sure , forgot that part. 1.7 at 4000rpm more less.

Be carefull because that turbo is designed to run with high back pressure , when there is no cat it tends to overboost a bit.

 

[bhodgkiss]

Thanks again guys,

Aside, which nozzles would be best for this turbo? PP764's or do i need to flow more fuel with a 10mm pump?

What power will 764's support?

I've messaged Struikie, waiting to hear back.

Thanks

 

[TDIfreak]

Race520 or DSS Ultime1 are good nozzles for the turbo. 10mm AFN pump is good, no need for bigger head. You can use bigger pump but 10mm is sufficient.

 

[bhodgkiss]

Thanks TDIfreak,

Can injectors be too big? I guess if they are far too big the spray isn't as atmoised as it could be with smaller, finer nozzles, that are suited to a given turbo, so the larger nozzles would be wasting fuel/using it inefficiently if there wasn't enough air?

With Race520's and the BV43 what sort of power/torque would I be looking at? (I'd be changing the clutch and fitting a FMIC, and then running about 1.7bar max. by the sounds of things)

 

[cog]

dont worry about the r520s i had a smoke free tune on mine till i asked for a bit more for the light haze. they work superbly as long as your tuner knows what he,s doing . they really woke up the mid to high rpm range even with stock pump . i had my pop pressures raised by 45 bar for better atomisation but ive heard plebnty having just the same results with stock opening pressures.
for pd 170 tubo power should be 160-170whp with r520s good tuning and intercooler or around 190bhp , power limited mainly by the stock 10mm pump

 

[G60ING]

Race520 or DSS Ultime1 are good nozzles for the turbo. 10mm AFN pump is good, no need for bigger head. You can use bigger pump but 10mm is sufficient.

Is the AFN pump equal in capability to the AHU pump?

I'm planning on running an AHU engine with a VNT 1749VA with an AFN manifold, PP764 (already have installed), PD130 intake manifold and 2.5 exhaust and downpipe. My goal is to get reasonable power of maybe 150whp with little smoke.

 

[DRVRFWND]

Is the AFN pump equal in capability to the AHU pump?

I'm planning on running an AHU engine with a VNT 1749VA with an AFN manifold, PP764 (already have installed), PD130 intake manifold and 2.5 exhaust and downpipe. My goal is to get reasonable power of maybe 150whp with little smoke.

the AFN and AHU pump is the same 10mm pump as long as they are both 5spd cars.

 

[TDIfreak]

AHU pump has different cam plate (DE015) and also the piston isn't identical even thought the diameter is the same. AFN has DE110 cam plate.

If you put 200bar or under with R520 you will get grey haze all the time. 230-260 is good.

Stock pump and R520 is about 400Nm max, not much more.
Stock pump and Ultime 2 I got 500Nm in an ALH. Hybrid VNT and R-cam.

Ultime2 is a bit much for BV43 but still usable (with good tuning).

The problem with large nozzle is that you have to use high pop pressure and the higher the pressure, the faster the springs get weak and the more often you have to put more shims in there to get the pressures back up again.

Therefore it's wise to use correct size nozzles.

 

[G60ING]

AHU pump has different cam plate (DE015) and also the piston isn't identical even thought the diameter is the same. AFN has DE110 cam plate.

If you put 200bar or under with R520 you will get grey haze all the time. 230-260 is good.

Stock pump and R520 is about 400Nm max, not much more.
Stock pump and Ultime 2 I got 500Nm in an ALH. Hybrid VNT and R-cam.

Ultime2 is a bit much for BV43 but still usable (with good tuning).

The problem with large nozzle is that you have to use high pop pressure and the higher the pressure, the faster the springs get weak and the more often you have to put more shims in there to get the pressures back up again.

Therefore it's wise to use correct size nozzles.

excellent insight. Thank you

 

[Rub87]

I tought AHU also had slightly lower timing piston cover, but this should not be a problem as you can easily advance the pump machnicaly so mimimum timing is 5° or so, and afterall you should do much more than 4000rpm to make good power with this turbo

 

[struikie]

Sure , forgot that part. 1.7 at 4000rpm more less.

Be carefull because that turbo is designed to run with high back pressure , when there is no cat it tends to overboost a bit.

mine runs 1720mbar...
not a hint of overboosting on my AHU with no cat and 63mm half-set Simons exhaust...

when we replaced the original AHU pump with the 11mm automatic ALH/AHH pump... power went from 185 to 206bhp with the same tune...


JW

 

[RomSL]

The problem with large nozzle is that you have to use high pop pressure and the higher the pressure, the faster the springs get weak and the more often you have to put more shims in there to get the pressures back up again.

How often do you recommend to check the pop pressure of the injectors with R520s?

 

[bhodgkiss]

Thanks again for the info guys,

So what do I actually need to change in my 10mm pump to make it 11mm? If its pump rotors (10mm to 11mm) then I need to change the housing they sit in too? Is this an easy job? Is the fuel pump in the engine bay or in the tank?

Struikie - I see you have the PD pistons. Is that pistons and rods? Are they visibly beefier - and known to be able to take say 500nm max instead of say 400nm for the standard non pd versions? Are you using the original crank and 5spd gearbox? Have you changed your gearbox oil for something that can withstand with higher contact pressures now you've doubled the torque? Or is the standard VW oil fine for this?

 

[TDIfreak]

How often do you recommend to check the pop pressure of the injectors with R520s?

About every 100 kkm.

 

[dillenger1]

Is the fuel pump in the engine bay or in the tank?

we're talking about the injection pump.Have you seen your engine lately? the 10mm to 11mm is the difference in diameter of the fuel distrubution plunger.If you dont know where the injection pump is,you cant do this swap!

one more thing.In no way is Volkswagen oil a standard anything!Volkswagen has always been way ahead of their time.

 

[bhodgkiss]

If I knew i wouldn't have asked

I could have looked in my manual but by asking on the forum it normally triggers responses that also point out short cuts and things not to forget, by all you nice knowledgeable people.

Struikie - sounds like the 11mm pump really helps and quickly becomes the limiting factor over about 180bhp. Worth knowing.

 

[TDIfreak]

Struikie - sounds like the 11mm pump really helps and quickly becomes the limiting factor over about 180bhp. Worth knowing.

Bigger pump is good for atomization and clean burn but purely powerwise, stock ALH 10mm pump gives 230-250 hp with Ultime2. I have done a few of those.

 

[bhodgkiss]

So back to the 11mm pump question:

what do i need to change my 10mm pump to 11mm please?

Is it this that needs changing?

My AFN engine definitely has the 10mm pump? And the 11mm version fits?

 

[Rub87]

sure.. if you want to use a complete 038 style 11mm pump you need to modify the bracket slightly

 

[G60ING]

Anybody have pictures of a BV43 turbo?

 

[Rub87]

I haveone of the commonrail version