How Do You Change A Fuel Pump On 06 Vw Jetta Tdi 1.9
Tuning the 1.9 TDI PD engines
Regarded by many as the best Diesel engine from the VAG group the 1.9 offers plenty of tuning potential.
It had a long production run and is still regarded by many enthusiasts equally a more than reliable engine than the later two.0 that replaced it.
The 1.9 TDi was used in a wide variety of cars from the VAG group and came in different power levels.
All had BOSCH injectors, and Bosch ECU'southward which are really sturdy and very protective of the engine.
If you want a quick beginner's guide to tuning diesels please run into our new video tutorial.
1.9 TDi Mutual faults & Problems:
In that location are some reports of the BLE or BXE engines breaking con rods.
The 2d generation PD engines were bullet proof as near of the kinks had been worked out which is more nosotros can say for the after two.0 TDI engines.
The 1.9 TDi is regarded by many as the all-time VAG group diesel engine.
Early engines suffered from croaky injector looms.
1.9TDi Engine codes
- PRE PD - 1Z, AHU, AGR, AHH, ALE, ALH, AFN, AHF, ASV, AVB, AVG
- PD engines - BSU, BRU, BXF, BXJ, ANU, ATD, AXR, BEW, BMT, AVB, AVQ, BSW, BJB, BKC, BLS, BSV, BXE, BPZ, AJM, ATJ, AUY, BVK, AWX, ASZ, AVF, BLT, ARL, BTB, BPX, BUK
1.9 R4 TDI - pre PD units
Engine configuration & engine displacement
inline four-cylinder Turbo charged Direct Injection TDI turbo diesel; compression ratio: 19.5:1
Cylinder caput & valvetrain
cast aluminum alloy; two valves per cylinder, 8 valves total, bucket tappets, timing belt-driven SOHC
fuel organisation & engine management
timing belt-driven Bosch VP37 Verteiler Pumpe electronic benefactor injection pump, direct injection
Engine codes with ability specs
89 bhp @ 4000 rpm; 149 lbf·ft @ 1,900 rpm - 1Z, AHU
89 bhp @ 3750 rpm; 155 lbf·ft @ one,900 rpm - AGR, AHH, ALE, ALH
109 bhp @ 4150 rpm; 173 lbf·ft @ 1,900 rpm - AFN, AHF, ASV, AVB, AVG
1.nine R4 TDI - PD version
Essentially, this revised engine has the same lesser end but has a revised cylinder head for the PD Pumpe Düse injectors.
Aspiration
hot-wire mass air period MAF sensor, cast aluminum alloy intake manifold, Garrett, KKK or Borg Warner variable turbine geometry turbocharger VGT, water-cooled EGR, bandage iron exhaust manifold
Fuel system & engine management
Pumpe Düse PD direct injection DI: engine-driven vane-type low-pressure fuel lift pump, iv camshaft-actuated via roller rocker arms loftier-pressure level Bosch 27,850 psi Unit Injectors with solenoid valve injection nozzles, Bosch EDC16 or EDC17 ECU
Engine codes with power specs
- 74 bhp @ 4,000 rpm; 155 lbf·ft @ 1,900 rpm - BSU
- 89 bhp @ 4,000 rpm; 155 lbf·ft @ 1,800−2,500 rpm - BRU, BXF, BXJ,
- 89 bhp @ 4,000 rpm; 177 lbf·ft @ 1,900 rpm - ANU
- 99 bhp @ four,000 rpm; 177 lbf·ft @ ane,800–2,400 rpm - ATD, AXR, BEW, BMT
- 99 bhp @ iv,000 rpm; 184 lbf·ft @ ane,900 rpm - AVB, AVQ
- 103 bhp @ iv,000 rpm; 177 lbf·ft @ ane,800 rpm - BSW
- 103 bhp @ 4,000 rpm; 184 lbf·ft @ one,900 rpm - BJB, BKC, BLS, BSV, BXE
- 114 bhp @ 4,000 rpm; 184 lbf·ft @ 1,900 rpm - BPZ
- 114 bhp @ 4,000 rpm; 210 lbf·ft @ 1,900 rpm - AJM
- 114 bhp @ 4,000 rpm; 229 lbf·ft @ 1,900 rpm - ATJ, AUY, BVK
- 129 bhp @ 4,000 rpm; 210 lbf·ft @ one,800 rpm - AWX
- 129 bhp @ iv,000 rpm; 229 lbf·ft @ one,900 rpm - ASZ, AVF, BLT
- 148 bhp @ 4,000 rpm; 236 lbf·ft @ 1,900 rpm - ARL, BTB
- 158 bhp @ 3,750 rpm; 243 lbf·ft @ ane,900 rpm - BPX, BUK
Remaps offer good power gains for very little outlay. Pre 2000 cars will require a bench flash in most cases but post 2000 cars volition generally be remappable via the OBD port.
Approximate power figures after a remap with no other mods.
(Bear in listen that peak ability figures are only a small-scale part of the equation, the whole torque band is improved).
- TDi90 = 116ps
- PD90 = 120ps
- PD100 = 130ps
- PD105 = 135ps
- TDi110 = 143ps
- TDi115 = 124ps
- PD115 = 150ps
- PD130 = 163ps
- PD140 = 175ps
- PD150 = 182ps
PD engines mostly requite a meliorate power proceeds than the original TDi engines. Further gains are possible on the standard block by uprating the turbo units.
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Best Engine Mods for your 1.9TDi
- Differentials - improving the diff on FWD cars using the 1.9TDi engine actually help yous go the ability downward.
- Mapping - remapping provides the most reward in terms of cost savings, aftermarket ECUs, and piggyback ECUs are all alternatives.
- Intake and Exhaust - Annotation that on their own these mods will NOT Add POWER in near cases, but they tin can assist raise power after other mods by removing the brake.
- Upgrades to turbochargers - forced induction upgrades and hybrid turbo upgrades, in item, are the almost efficient way to increase air supply, allowing you to burn more than fuel and brand more power. It is one of the most plush upgrades but provides the best gains.
- Fuelling upgrades, the injectors and fuel pump will need uprating for larger ability gains.
- Intercooler upgrades - the stock intercoolers are restrictive when running maps so swap in an FMIC that flows better and resists heat soak for longer.
Alarm: Practise NOT FIT A LIGHT SINGLE MASS FLYWHEEL TO THIS ENGINE! The vibrations will bulldoze you crazy and gearbox life will be reduced.
Typical phase 1 mods often include:
Remap, Lighter flywheel (stick with dual mass though, SMF'southward are not peachy on the ane.9), Sports exhaust, Panel air filter.
Typical stage ii mods often include:Ported and polished head, Power/Sport clutch, Fast road cam, fuel pump upgrades, high flow fuel injector.
Typical stage iii mods often include:
Engine balancing, Internal engine upgrades (pistons/head/valves), Competition cam, Adding or upgrading forced consecration (turbo/supercharger).
Differential upgrades to maintain traction on the 1.9TDi
You volition get lots of traction issues around 250bhp, and then bear this in mind, while your wheels spin you won't be moving!
For a car that is used on the road in unlike weather conditions, I think the Torsen diff is the best choice.
Torsen ways "Torque Sensing," and it is very subtle in how it works. It comes on very slowly and gradually.
There are some LSDs that aren't very noticeable, and there are Torsen diffs that are a niggling more than quick. This all depends on the diff maker and how the car is set upwardly.
Torsen diffs can be establish in a lot of production cars. LSD diffs are normally institute in cars with a lot of power or a high price. A, B, and C are the three main types of Torsen diffs. Each one has different applications and characteristics, and some aren't good for everyday use.
Ane of the diffs our members recommended was a Quaife LSD. Quaife besides makes ATB diffs.
Remapping the 1.9TDi
How does VW fix the factory maps? It accepts that some countries' CO2, HC, and NOx emission targets differ, necessitating a fudged arroyo - the everyman common denominator if yous will.
Manufacturers do not want customers to be inconvenienced by mechanical failures or poor fuel economy, therefore they build in a large tolerance.
Depending on how effectively the components are machined and assembled, the power output of each engine tin can vary by as much equally 20bhp. Rather than examine each automobile individually and create a custom timing map, they employ a i-size-fits-all approach.
Manufacturers too employ remaps to create multiple power versions of the aforementioned 1.9 TDi engine, lowering insurance rates and improving fuel economy.
So at that place is enough of scope to extract more power from your 1.9Tdi with a remap.
Downsides of remaps.
Service your machine more regularly, possibly decreasing the interval.
A map optimised for high octane gasoline will demand y'all to repair components that neglect due
Additional power puts more pressure on components like turbos, hoses & pipes, and injectors.
Months afterwards a remap, an engine's weak areas resurface. remap bug, see our instructions.
A remap volition usually reveal turbocharger and clutch bug.
Also, 1.9 TDi turbos may fail, and critical components like pistons and bearings must be maintained. NASP remaps? A remap will only add a few BHP without a turbo (10 percent is typical).
TorqueCars encourages non-turbo cars to modify first (cams, pistons, increment compression, engine rest, air intake, exhaust, head work, bigger valves etc...)
After that, a remap may help you get the most out of them.
A remap frequently adds heave from lower rpm, making the turbo operate quicker and hotter.
If you don't let the turbo cool, the oil may deteriorate, necessitating a costly turbo repair. Installing a turbo timer will too help cool the engine.
Not all maps are equal and so don't compare peak power claims
Be wary of elevation ability claims. Annotation: Some tuners are known to create a power blip or surge to draw attention and capture headline ability statistics.
See the graph below for an example.
The crimson trace, at 200bhp, is not that impressive, the superlative power happens quite high up and is simply a blip, whereas ability for the rest of the RPM range is substantially down.
However, the green trace indicates a consistent growth in ability beyond the RPM range and although only 175bhp information technology will requite ameliorate power than the 200bhp map.
On the ane.9Tdi you would want tiptop power early at 2500rpm, which is not bad for an engine that redlines at 5000rpm.
On a map, we desire to see a overnice smoothen torque climb with no dips or troughs.
Injector upgrades on the 1.9TDi
The one.9 TDi injectors on the PD130, PD150 will exist expert for 240bhp, injectors on the lower powered engines including the popular PD100 PD105 and PD115 units will need uprating at 170bhp.
The PD150 injectors are a good pick to upgrade with, or yous could source some loftier performance ones.
one.9 TDi turbo upgrade options
Is In that location a Reason to Upgrade Your Turbo?
Many motorists choose to replace or raise their cars' turbochargers for the following reasons: Turbocharger upgrades are an splendid style to boost a vehicle's performance and one of the well-nigh impactful.
Turbos wear out with time, needing periodic replacement. Additional recent turbos take apply of newer technological breakthroughs and provide vehicle owners with more addition possibilities.
The manufactory 1.9Tdi turbos are supplied for cheapness and reliability not functioning and so thankfully in that location are many upgrade options around for these. Here are some that TorqueCars have found to be particularly constructive based on feedback from our members and my own experiences.
On these engines you can choose from the GTB2566VK adept for upwardly to 245bhp maxing at 3300rpm. GTB2260VK expert for up to 315 bhp maxing at 2800rpm, GTB2056VK good for up to 255 bhp maxing at 2700rpm and the GTB1756VK proficient for up to 235bhp maxing at 2600rpm.
- GTD2872VRK 375-400hp @3350rpm 40psi
- GTB2260VK 350hp @2850rpm 35psi
- GTB2056VK 300hp @ 2750rpm 34psi
- GTB1756VK 250hp @ 2650rpm 34psi
There is as well the GT2052V good for 225bhp at 2200rpm which would exist our choice on a route machine at is spools up quite quickly but still provides decent boost levels.
Other Turbo upgrade options on these engines exist if you are prepared to change the pipework and manifolds. These include the GTB1749V producing upwards to 205bhp from just 1900rpm, and GTB1756V which is good for around 225 bhp. Some companies offer hybrid turbos which tin can button power levels to 240bhp or more with the right boosted mods.
NB: Turbos volition require conversion to Vacuum actuators and take the VNT organization set up.
Choose the turbo where the power band sits in your most-used rpm range, the larger power turbos tend to come up on boost later.
Guide to Hybrid turbo upgrades for the one.9TDi
A hybrid turbo is a direct replacement for the OEM turbo, but with modified internals to meet your ability needs they are generally commodities on upgrades every bit they typically retain the OEM housing and manifold design from your 1.9TDi.
By modifying the profile of the exhaust side impeller, you may increase the turbo'southward spool time, extend the ability range, or increase peak end ability.
Information technology is oft a tradeoff, since you cannot take all of these advantages and must select the all-time solution for your circumstances. Additionally, modifying the intake compressor'due south profile may have a significant influence on the amount of air that tin can be drawn into the engine.
Turbochargers use ii distinct kinds of bearings.
Bearing options include thrust and brawl types. Almost OEM turbos employ thrust bearings because they are less expensive to manufacture, but when excessive ability is practical to them, they might fail, resulting in oil leaks and premature turbo wear.
A ball begetting turbo will oft spool up faster than a thrust bearing turbo and can handle far more power so is the preferable choice. But nosotros are now seeing ceramic and cryo treated bearings which farther better reliability.
Not all OEM turbo housings can be changed to convert to brawl bearings; instead, an OEM-shaped turbo unit is created to suit the upgraded internals.
Additionally, the design of the air intake pigsty has an effect on the turbo'south menstruum characteristics.
Any ridges, pits, or seams in the metal surface might generate turbulence, impairing the airflow backdrop. Consider the following advantages and disadvantages when determining the parameters of your hybrid turbo.
On a track where yous spend almost of your time at high rpm this is fine merely in 24-hour interval to mean solar day driving lots of lag can be frustrating to drive.
1.9 TDi tuning essentials
110 and 90 VE one.9 TDi Engines will demand uprated fuel injectors too, the standard injectors on these engines are not good at higher power figures. The 150 head bolts are strong, in all other engines yous may feel head lift on stock bolts at large power gains.
Fit uprated head bolts or get some bolts for the 150 and fit these instead.
When pushing another 50 bhp through these 1.9 TDi engines information technology is recommended to get a hard pipe kit, joints and pipes that are former are more probable to dissever apart when you run higher air pressures through them.
New clutches are usually ok with ability gains to the 220bhp. Worn clutches volition oft be ok but it depends on the treatment and status of the clutch. Worn clutches seem to skid in nearly half of the cases where large power gains have been fitted.
Most ane.9TDi OEM turbos are the same but the downpipe blueprint and manifolds varied according to the blazon of vehicle they were mounted in.
Newer i.9 TDi CR diesel fuel engines are much much cleaner, and they have improve fuel management, and pollution reduction measures but lots of brusque journeys can lead to clogging up of the DPF (Diesel particulate filter). See our guide on how to clean a DPF for more info.
1.9 TDi Intercooler upgrades
A larger intercooler will also better resist rut soak and would exist a adept upgrade on these engines.
In a ane.9 TDi turbo, the cold intake charge and hot exhaust temperatures are near each other inside the turbo. This tin be a problem. The big rise in air intake heat is caused by the air itself beingness compressed, so even a supercharged engine will benefit from having an intercooler to aid information technology absurd down.
Air gets hot when it is compressed. If you lot have ever felt the nozzle on a tyre pump you lot will know that when air is compressed it gets hot. There is more oxygen in the colder the air is, considering nosotros learned about this in our chemical science and physics class.
Why is this important?
A one.9 TDi that has more than oxygen has more than power because it can burn a lot of gas. You lot can read more than virtually air intakes in the article.
In a motorcar, what is an intercooler and what does it do?
An intercooler is a radiator that cools the air charge before information technology goes into the one.9TDi engine.
You should put an intercooler in front of the radiator so that it gets a lot of dainty, cold air. Afterward, the air intake filter and the turbo or supercharger, where nearly of the estrus is added, it would be piped into the car.
An intercooler that is well-designed can requite you 5% to 10% more power from your mods, and resist estrus soak for a longer time.
Keep in mind that y'all desire to get as much air into the engine as possible, so if the internal core of the intercooler is in the mode, y'all will lose ability.
Bigger isn't ever improve, though!
TorqueCars would expect a pressure level drop of between.v and.9 psi for a boost level of 15PSi. In the worst case, some applications could lose 1.3 psi. It'southward not the intercooler'southward design that caused the whole loss of pressure level, it's partly down to the reduction in temperature, so don't blame information technology for the whole drib in pressure.
In operation cars, weight is always a concern. Many aftermarket intercoolers are both lighter and more powerful than factory intercoolers, which makes them a good choice for these cars.
As a general dominion, if the intercooler is a little bigger, information technology will be ameliorate at cooling, only it volition as well make the auto move slower.
There should be a lot of thought put into how much extra drag this will add to the cooling. More air stays in the intercooler, the meliorate it will cool yous downwardly.
Some cars accept a spray nozzle that can be used to spray the intercooler with water or nitrous, which lowers the intake temperature even more as the liquid evaporates using the heat from the air that passes through the intercooler. This helps the car run more than smoothly.
Between 5% and 10% of power is gained from a more than efficient i.9 TDi intercooler design over the mill one (bold there was a restriction which depends on the way the engine has been tuned and setup). This is based on a temperature drib of 35C-40C. The bigger the difference betwixt intake temperature and ambience temperature, the more cooling issue there will be.
As time goes on, even the most efficient intercoolers will get hot. When you lot drive for a long time with a lot of high-boost, the intercooler starts to go hot.
In general, the bigger the intercooler, the longer it can withstand heat soak.
Please help united states of america complete this article, if you are aware of any 1.9 TDi engine codes we have missed, mutual issues or upgrade options including turbos please let u.s.a. know, we desire to make this every bit comprehensive as possible.
Tuning the intake and exhaust on your ane.9TDi
Next, we'll examine the best options to better the ane.9 TDi intake and frazzle to verify adequate engine air and frazzle menstruation. Delight notation that on this engine you should be fine on the stock setup to around 220hp.
A comprehensive consecration setup maximizes power improvements if yous hit a brake. We recommend a high menstruation panel air filter on all one.9Tdi, they will ameliorate the "off throttle" engine running and requite me a piddling more than fuel economy on mine without impacting on functioning.
Opening the air intake port to match the intake manifold would non help much unless a step obstructs airflow into the ane.ix TDi engine. And so most DIY port matching is done on exhaust ports simply we don't really encounter a need on the ane.9 TDi engine.
Extending the port size is only necessary for highly tuned engines when the port size has become a bottleneck and VW did a great job on the blueprint on the 1.9Tdi.
The greatest ability improvements are generally between one.five and 2.5 inches.
Please join our friendly international forums if you desire to talk over whatever aspects of 1.9TDi tuning in item and let us know in the comments below what mods you lot've done or pass on whatever tips to our readers.
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