Golf 4 TDI ASZ auf 200 PS oder mehr mit Leistungssteigerung

Hi

As stated in the title, I want to increase the power of my 2003 Golf 4 TDI 96kw ASZ to approximately 200hp. Mileage: 130,000 km.

I understand that several parts need to be replaced during the performance.

I just bought a brand new GT1749VB. Not yet installed.
New oil supply and oil return lines are also installed.
R32 intake and air filter box are already installed. Air mass sensors and air filters are new.
Ordered: Seat Ibiza Cupra front-mounted intercooler, adapted for use in the Golf 4.
Also, a Sachs performance clutch (organic) has also been ordered. A flywheel is not suitable due to noise.
Since I have an ASZ engine, I have already installed the 550mm nozzles.
Are the 200hp and 400nm figures achievable with these components?
If the head gasket is overheating due to performance, I directly install the 12.9 head bolts from ARL. Are there perhaps stronger screws or bolts?

I wanted to create a kind of progress thread, where I could post my updates.

No, even I realize that something is missing, or have I missed something?

You mean the chip adjustment . Yes, it will be installed at the end, once all the components have been fitted.

While I don't really care, but if the voting process might be handled by Rainer, then I would ask him beforehand what would make sense to include, even though you already have specific ideas.

I would prefer to have Rainer do the work, but I live in Cologne, Germany, and traveling to Switzerland for the software customization is a bit too far for me.

In Switzerland, it's beautiful - take a vacation

That's another thing that comes to mind.

My AGR has been "defective" for ages . Now I've noticed that the internal components of the AGR are quite large and unnecessarily disturb and hinder the airflow. The AGR actually creates a bottleneck between the LLK (presumably the intake manifold) and the intake manifold.
My idea now is to completely remove the internal parts and weld the holes to eliminate the narrow passage.
Now, however, we also need to consider the auxiliary air intake valve, which is located in the AGR (Exhaust Gas Recirculation) system. Its cross-section also somewhat hinders the airflow. But I think the cross-section of the valve is significantly smaller and it is located much more favorably in the intake manifold. Removing the storage compartment is not an option.

Now my question to the experts. Could this mean anything, or should I save the effort?

I would, on this occasion, remove everything and install a replacement pipe. You can buy this ready-made.

Also, auch bei mir ist die Abstellklappe defekt (und ich sage es nicht, ich habe tatsächlich ein Steuergerät, das diese Funktion nicht unterstützt, und es zieht die Klappe jedes Mal sofort zu und schaltet dadurch den Motor ab - dazu gibt es auch einen Thread hier). The perceived difference when stopping is minimal and is only noticeable when the engine is completely cold.

wingmaster wrote:

I would prefer Rainer to do it, but I am from Cologne, Germany, and driving to Switzerland for the software customization is a bit far for me.

Then you will have to look around for some software that doesn't just say "200PS" but actually has that performance.

Just now, another piece of work from a young, dynamic tuning company has landed on my computer, which supposedly brings a Leon ARL up to 430 Nm / 204 hp (since the software base is the same as the ASZ, this example is already transferable to your case).
If the inner workings of the software are well understood, then real-world figures such as those for the ARL files can be calculated to be approximately 350 Nm and 180 PS. The remaining missing values (including distorted boost pressure diagnostic data and other factors) are the result of various errors and lack of knowledge on the part of the tuner.
Incidentally, the owner of the modified Leon also lost a comparison against a similar car, whose software was cleanly calculated to produce a mere 365 Nm / 185 hp, and did not fare well.

But perhaps it's good that only a tiny fraction of the alleged "> 400 Nm" tuning files for the 1.9 TDI engines actually unleash such power – simply to prevent a continuous failure of clutches and gearboxes, which would damage the tuning industry's reputation for irresponsibility towards customer equipment.
However, if drivers with >400 Nm engines firmly believe in it (because their tuner, of course, has a full plan, otherwise they would have gone somewhere else!), they can calmly argue about it, and otherwise, little damage occurs

Quote:

My parking flap is also defective (this is no joke, I currently have an ECU in there that doesn't seem to support this function, and it keeps closing the flap immediately, thereby shutting off the engine

It seems like someone simply tried to disable the AGR in the software with minimal effort: this exactly creates that error pattern.

To optimize the software, you could also contact XXX from XXXX. He is a master of his craft.

edit: No advertising please

My parking flap is also defective (this is not a joke, I currently have an ECU in which this function does not support, and it closes the flap every time immediately, thus stopping the engine It seems that someone simply tried to disable the AGR in the software with minimal effort: this creates exactly that error pattern.


Maybe, Ulf. I haven't worked with this control device or the software that was on it at the time, but at that time, I simply disconnected the solenoid for the liftgate. Then there was silence, and therefore I now also know how an ASZ / ARL without a closing door feels.

I have edited Trebor's post. Advertising for anyone is not desired here.

Can the property owner also speak up? I'm sure the public would also be interested in his opinion on the renovation. I would also like to have even larger nozzles installed.

@ EMSim ASZ:
You can find Rainer's recommendations in the shop. There are quite precise definitions for exhaust nozzles and turbochargers suitable for >200 HP, always with the appropriate MKB.
haithamina

EMSimASZ wrote:

can the property owner also speak up? It would definitely also be interesting to the public to hear his opinion on the renovation. I would also install even larger nozzles.

But he's going to the competition anyway?

You're so funny... I'm going to eat cookies now, that's more sensible.

Hello everyone.

There are some new developments. Intake cooler and clutch are there.
Basically, I could implement everything now.
I need to figure out how to incorporate the charging pressure sensors into the piping to the LLK.
Okay, I've also considered using larger nozzles. But I only want "just" 200 hp, and for that, the 550mm nozzles should be sufficient.

So far, no one has engaged with my theory about cleaning the AGR without internal intervention.
So, that's really incredible, the amount of tissue that's being removed. I am fully aware that I cannot expect any miracles, but even a minimal improvement in responsiveness would be worth the effort.

Rainer K. wrote:

Can the homeowner also speak up? I'm sure the public would also be interested in his opinion on the renovation. I would also like to install larger nozzles. EMSimASZ wrote: But he's going to the competition anyway? You're so funny... I'm going to eat cookies now, that's more sensible.

I will come to you to have my ASZ modified. I don't want just any software, but yours because you really understand engines. I will be driving with a friend and taking turns. I've just calculated the distance. It's 600km from me to CH-9453 Eichberg. That's still doable, just one day of driving. But it's worth it to me if everything goes according to plan afterwards.

Here are a few pictures of the parts that are already here.

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