Difference Between 90hp And 115 Hp Heads

[nasonjs]

I have an 03 galaxy 1.9 tdi 90hp. It needs a new cam and bucket. I was thinking of swapping the heads with another. Is there any difference between the 90hp and 115hp heads?. Can I use any other heads such as the golf/bora/passat etc.

Thanks

[sepulchrave]

Yes, all the VW 1.9 PD heads are the same casting etc.

 

I believe that they are all interchangeable irrespective of which VW, Seat, Skoda they come from.

 

The BHP differences are entirely down to turbo boost and mapping which is why chip changes are so spectacularly successful with these engines.

 

You would be better advised to fit a remanufactured head complete with cam from someone like:

 

http://www.ivorsearle.co.uk/public/index.asp

 

They are not very expensive and you get a good guarantee to boot.

[Willie Krashitt]

Sephulcrave,

 

You may well be right regarding the cylinder head, but you are 100% WRONG on the calibration.

 

The difference between 90, 115, 130, 150PS etc engines is most definately NOT down to just mapping. They ALL have unique fuel injectors, and only the 130/150 have a common turbo. 130/150 also get a much larger intercooler, air cleaner and pipework,a revised water pump, exhaust system and an absolute host of other bits and bobs. The 90PS even has different pistons and con-rods to all the others. Anyone who tells you different is lying.

 

The ONLY way a 90PS can be made to produce 115, 130PS etc (and same goes for 115) is to take calibrated factors such as turbine speed, turbine temperature, cylinder pressure and smoke limits beyond what is designed or legally acceptable. As an example, a turbo that is running just 40 degrees too hot can have its life reduced from 1000's of hours to just 2.

Overheating and blown head gaskets are very common with VW (and other manufacturers) engines that have been chipped.

 

George.

[roy202]

Sephulcrave,

 

You may well be right regarding the cylinder head, but you are 100% WRONG on the calibration.

 

The difference between 90, 115, 130, 150PS etc engines is most definately NOT down to just mapping. They ALL have unique fuel injectors, and only the 130/150 have a common turbo. 130/150 also get a much larger intercooler, air cleaner and pipework,a revised water pump, exhaust system and an absolute host of other bits and bobs. The 90PS even has different pistons and con-rods to all the others. Anyone who tells you different is lying.

 

The ONLY way a 90PS can be made to produce 115, 130PS etc (and same goes for 115) is to take calibrated factors such as turbine speed, turbine temperature, cylinder pressure and smoke limits beyond what is designed or legally acceptable. As an example, a turbo that is running just 40 degrees too hot can have its life reduced from 1000's of hours to just 2.

Overheating and blown head gaskets are very common with VW (and other manufacturers) engines that have been chipped.

 

George.

 

nice comment i knew the injectors were different but didnt know about the size of the intercooler etc, its something ive wondered for a while so thanks for that.....

[sepulchrave]

Sephulcrave,

 

You may well be right regarding the cylinder head, but you are 100% WRONG on the calibration.

 

The difference between 90, 115, 130, 150PS etc engines is most definately NOT down to just mapping. They ALL have unique fuel injectors, and only the 130/150 have a common turbo. 130/150 also get a much larger intercooler, air cleaner and pipework,a revised water pump, exhaust system and an absolute host of other bits and bobs. The 90PS even has different pistons and con-rods to all the others. Anyone who tells you different is lying.

 

The ONLY way a 90PS can be made to produce 115, 130PS etc (and same goes for 115) is to take calibrated factors such as turbine speed, turbine temperature, cylinder pressure and smoke limits beyond what is designed or legally acceptable. As an example, a turbo that is running just 40 degrees too hot can have its life reduced from 1000's of hours to just 2.

Overheating and blown head gaskets are very common with VW (and other manufacturers) engines that have been chipped.

 

George.

 

Thanks for all the additional info there. I was really only referring to things relevant to the OP's question about the cylinder heads. I am certain I am right about that since I have supplied many such heads on an exchange basis for a wide variety of VW based vehicles.

 

I was not aware that the unit injectors themselves were different since we simply bolt the existing ones into the new head casting, I was aware that there were many detail differences between the powertrains of the engine variants but didn't want to muddy the waters since it was outside the scope of the reply needed. Those of us with knowledge to share with members really need to stick to solving those problems rather than overcomplicating matters and losing the focus of the thread. Please do point out if any of the advice I freely give misleads the OP in solving his particular problem, you will find that I do not tend to bother posting in most threads unless I have something useful to contribute, hence my lowish post count.

 

Anyway, back on topic here, I stand by my assertion that you can use any PD head on your engine, and maintain that you will be better off fitting a completely remanufactured head which comes complete with new cam and followers already installed, you will need new stretch bolts for the unit injectors and head fitment and a new top gasket set.

[seatkid]

OP said there was a stripped camlobe, so he will need at least one new unit injector.

[sepulchrave]

Negative.

 

Damaged camlobe will be for valve actuation running on a collapsed or heavily spalled hydraulic bucket.

Camlobe for unit injector runs on large overhead roller rocker which in turn actuates injector, roller may be scored but will almost certainly be reusable.