Engine upgrade: 130 hp to 160 hp?

Hello,

I once went through some documents and compared the BPX (Ibiza Cupra 160 hp) with the ASZ and ARL engines.

Result (for fiscal years 2003-2005):

The BPX engine block (038 103 101 AB) is the same as that used in the ASZ and ARL engines in the Volkswagen Golf 4, as well as the SEAT Leon/Toledo.
I don't understand why the Ibiza and Polo models have different engine options.
The cylinder head is the same again.

2. The BPX water pump is equivalent to the ARL, while the ASZ models have different pumps.

In addition, there are various other chargers (not all of which are the same, even those from ARL and BPX), as well as external components like liquid cooling systems, etc.

4. Otherwise, all the power-transmitting components are identical in the ASZ, ARL, and BPX engines (pistons, crankshaft, etc.), and this also applies to the engine control system (camshaft, timing belt, etc.), the particulate filters (DPFs), and even the oil pump and oil injectors for piston cooling.

In plain terms:
Basically, when working on the engine itself, you only need to replace the water pump and turbocharger, and a Golf 4 with an ASZ engine will have the hardware of an ARL engine. Let's not talk about the software for now.


But what is the significance/implications of the other ASZ engine blocks used in the Polo (038 103 101 AJ) and Ibiza (038 103 101 AG)?
Could these components become weak points (e.g., strength, coolant channels...) if the rest of the system is upgraded to a BPX level?

Somehow, the idea of a "Polo Cupra" with that long gearbox seems quite appealing to me.

Ulf, could it be that the block has a different part number, since the recordings for the auxiliary components are definitely different. Don't the Ibiza and Polo 9N, for example, have an electrically powered power steering system, whereas the Golf IV platform still uses the hydraulic system driven directly by the engine? Could that be a possibility? The material is certainly the same.
The turbochargers only differ by the last letter (both have the GT1749V type), with a "G" for the ARL and an "F" for the ASZ, or am I misinformed? Do you know what changes were made? Are the turbine blades arranged differently? From a cross-sectional view, both chargers appear identical.

matthiasTDI96 wrote:

Haben Ibiza und Polo 9N nicht z.B. eine elektrisch angetriebene Servolenkung wo hingegen die Golf IV Plattform noch mit der hydraulischen Anlage vom Motor direkt angetrieben herumfährt? Wäre das eine Möglichkeit? Das Material ist doch sicher das Selbe.

The steering issue is correct, and the material aspect seems likely.
However, the Ibiza Cupra likely also has electric power steering and still received the ARL block...

Quote:

Die Turbolader unterscheiden sich doch nur durch den Endbuchstaben ( ist doch bei beiden der Typ GT1749V ), beim ARL das G beim ASZ das F oder bin ich falsch informiert. Weißt du was dort geändert wurde? Sind die Turbinenschaufeln dort anders angeordnet? vom Querschnitt sind doch beide Lader identisch.

You are correct that the inlet and outlet flanges have the same dimensions.

Nevertheless, the ARL compressor must somehow be optimized for a higher mass flow rate, because otherwise, one could have used the ASZ charger .

Okay, I hadn't thought about the CUPRA. Well, I also assumed that the turbocharger was different, which makes sense. What I would have been interested in is what exactly is different. As I said, the only difference I know of is the "G" instead of the "F." Probably, it moves a bit more air because the intercooler system seems to be slightly larger.
I have one more question while you're working on this. Does the ARL engine have a different (thicker) head gasket? My documents (specifically, the Volkswagen owner's manual) indicate that it has a compression ratio that is 0.5 lower than other engines.

matthiasTDI96 wrote:

I have one more question if you're currently looking into this. Does the ARL engine have a different (thicker) head gasket, since my documentation (specifically, the VW owner's manual) indicates that it has a compression ratio that is 0.5 lower.

Well... the pistons, connecting rods, crankshaft, cylinder head, and the 3 different types of head gaskets are all identical.
Wenn allerdings der ARL-Zyl.block eine Idee höher sein sollte als beim ASZ, ließe sich damit natürlich auch eine geringere Verdichtung erreichen . . .

EDIT (after belated reflection ).
In the VW Golf 4 and Seat Leon/Toledo, the ASZ and ARL engines also share the same cylinder block.
This again speaks in favor of the same overall height, because otherwise the ASR (Anti-Slip Regulation) system would have a lower activation threshold in the Golf and Leon than in the Ibiza/Polo.

Does anyone perhaps have access to repair manuals for ASZ and ARL?
-> When the cylinder head height varies, the piston protrusion reference dimensions for selecting the head gasket must also be different.

Quote:

He probably digs up a bit more material since the intercooler piping is also somewhat "more substantial".

What is different about the intercooler system?

The auction house is advertising that they can tune 130 HP engines to produce 150 HP using a TDI turbocharger.
So, the charger would be compatible in terms of hardware, but wouldn't actually do anything useful?

As written, the chargers are almost identical. It's likely that only some adjustments were made to the turbine geometry. Whether swapping the charger will make a difference is questionable without adjusting the electronics.
I can imagine that, but it doesn't necessarily have to be the case.

It's different.

Turbocharger.

Intercooler and hoses!

PD elements.

ECU.

Exhaust system.

Air filter with air duct.

Best regards,

SD16 wrote:

It is different:

Which engines/vehicles did you compare here?

Quote:

PD elements

ASZ, ARL, and BPX all share the same phone number: 038 130 073 AL.

Quote:

Exhaust system

The ASZ engine in the Polo/Ibiza and the BPX engine share at least the same catalytic converter component, located directly behind the turbocharger.
And as far as I know, the catalytic converter is usually the limiting factor (in terms of being the weakest link) for the exhaust system's performance.

As far as I know, the LLK (likely referring to a specific document or code) is definitely different between the ASZ and the ARL.
In the case of ARL (presumably referring to a specific device or component), it should be flatter and larger. Consequently, there is a distortion/problem.
also different from what happens at the ASZ.

If the connections of the two chargers, ASZ and ARL, are the same -

What would happen if the ARL charging station were simply integrated into the automated storage and retrieval system (AS/RS)?
Without making any changes to the engine control unit (ECU)?

Would the local exhaust ventilation (LEV) system from the air handling unit (AHU) have difficulty removing the excess air at the air-lifting loader?
to cool down?

I only know the 160 hp TDI engine in the Seat Cupra.
I think it's the same with Volkswagen.

Best regards,

Klima96 wrote:

As far as I know, the LLK (likely referring to a specific document or code) is definitely different between the ASZ and ARL. In the case of ARL (presumably referring to a specific device or component), it should be flatter and larger. Consequently, there is a distortion/problem. auch anders als beim ASZ .

I already wrote that at the very top.
Hinzu kommen jeweils andere Lader . . . und externe Teile wie LLK usw.

Quote:

What would happen if the ARL charger were simply installed in the ASZ? Without making any changes to the engine control unit (ECU)? Would the local exhaust ventilation (LEV) system from the air handling unit (AHU) have difficulty removing the excess air at the air-lifting loader? runter zu kühlen ?

Why is there more air being moved by the ARL charger?
To achieve this, the boost pressure would first need to be adjusted, but without modifying the engine control unit (ECU)?
The ARL loader alone could potentially cause a larger turbo lag.

The ASZ and ARL loaders have different connection pieces.
The intercooler routing is different as well.
ASZ = Liquid cooling system in the frame triangle.
ARL = LLK in front of the water cooler.

My mechanic said that it might be possible to install the ARL turbocharger in the ASZ engine, but you would have to find a way around the expensive hoses.


Regarding the differences again:
Does the ARL engine have stronger cylinder liners and different connecting rods compared to the ASZ engine?

Quote:

Hat der ARL im Vergleich zum ASZ nicht auch staerkere Lagerschalen und andere Pleuel?

No, everything has been the same since 2003.

Then, from this production year onwards, the ASZ received the reinforced parts of the ARL, correct?

Yes, Ulf has done some good research on that matter .