270BHP TDI Quattro

[freezebox]

I love my A3 sportback 2.0 TDI, only problem is I've got used to the speed/power of the 170PPD engine and want something a bit quicker. Unfortunately an S3 sportback is WAY out of my budget so I've been pondering making some modifications to my car.

• Uprated DMF/Kevlar clutch.
  
• Hybrid turbocharger rated to 270BHP or I can also get one rated to 250BHP but will I regret not getting the bigger one? It's only £100 difference.
  
• New mapping

Car already has EGR removed and DPF gutted.

After doing my research I've realised the maximum BHP the injectors can flow is 280-300bhp with a moderate smoke. I want to build the ultimate sleeper.

Can anybody think of anything else I may have missed out as I'm trying to budget to see if I can afford it/if its worth it.

 

[hollows wife]

probably a larger intercooler

 

[Johnny Bravo]

And exhaust, to lower the EGT...

 

[adamss24]

You will be better off with a larger turbo no older than 10 years technology. Hybrids are fine as well but they need careful matching of components and are not as reliable as stock turbos. Personally i will only fit a gtb 2056 or later gtb2060 ball bearing turbo... best spool and low egt from the box and will support your power goal without much bother and be more reliable at the same time...drop me a pm if you need further info, have done quite a few fast diesels in the past so i know what i'm on about...

Chris

 

[Sayam]

I'm curious as to where you read the injectors will go to 280-300? I know someone who has a Mk5 Golf 4Motion at around 300BHP and he had new injectors...

 

[freezebox]

I'm curious as to where you read the injectors will go to 280-300? I know someone who has a Mk5 Golf 4Motion at around 300BHP and he had new injectors...

Hi mate,

Contacted darkside and various other tuners.

 

[millsy4002]

I got a 2007 tdi 2.0 quattro sportback and would like to see where this goes, if you can get anywhere near 250-260 sounds good, im about 200-210bhp not sure as previous owner had it mapped

 

[freezebox]

The ball is now ROLLING.

This is officially now a build thread. Uprated kevlar clutch, pressure plate and DMF have just been purchased! Going to take a couple of weeks to come though

 

[shadow1993]

U will definitely need a bigger inter cooler and an exhaust that is less restrictive i guess?

 

[freezebox]

U will definitely need a bigger inter cooler and an exhaust that is less restrictive i guess?

Removed all dpf cat silencer and backbox already

 

[Keram]

I believe for this power SMF is the only way to go. Would be interesting to see how DMF works.
Don't forget to add new MAP sensor (4bar) to the list.

PS. wouldn't be GTB22** needed for reliable 270hp?

 

[freezebox]

I believe for this power SMF is the only way to go. Would be interesting to see how DMF works.
Don't forget to add new MAP sensor (4bar) to the list.

PS. wouldn't be GTB22** needed for reliable 270hp?

I was originally going to go for an SMF, but was strongly advised against it due to the noisiness.

 

[Sayam]

Are you going for the S3 intercooler? I'm looking forward to this build!!

What turbo you using?

 

[freezebox]

Are you going for the S3 intercooler? I'm looking forward to this build!!

What turbo you using?

Most likely a ball bearing based 11 blade hybrid pal, considered a gtb 2260 but it requires so much more work and expense such as building a manifold etc. This way its just bolt on. After talking to a few companys and a guy with a 330bhp bmn passat Im pretty sure I can get away without upgrading the intercooler as they are all running stock, but I will upgrade if its needed.

 

[shadow1993]

Keep us posted, very interested!

 

[adamss24]

Stay with a 6+6 compressor, they produce much more boost than the 10/11 blades compressors. One thing to consider is volumetric eficiency, you will need flow to spool big turbos...which stock engines lack.

 

[james.allan.923]

I'm going to watch this thread closely. I'm interested in getting my tdi quattro to this kind of power too.

 

[millsy4002]

Mental TDi's for everyone!!

 

[freezebox]

Mental TDi's for everyone!!

Lol, im looking forward to getting tailgated, dumping the clutch and covering them in thick black smoke

 

[hollows wife]

Pain in the butt cleaning all the soot off the back of the car when mapped this way overfuelling to keep egt temps down .
As for the 270 bhp with a ppd ecu and injectors i doubt you will see more than 250 tops .
Nephew had the a4 with hybrid etc and rs tuning at leeds couldnt get it past 238bhp without clouds of smoke .cost him around £100 per bhp extra from a standard remap .

 

[Rick @ Unicorn Motor Dev.]

I don't think you will see 270 either. Don't be tempted to go with too big a turbo. Have you driven a car larger turbo'd diesel? You might not like it.

The reason for the smoke is that you are injecting for a large duration of crank rotation, to the point where the exhaust valve is open and fuel isn't getting burnt properly. The injectors are already working quite hard on your current map. How much smoke you can tolerate is personal, but I can tune it to whatever level you want

Rick

 

[freezebox]

I don't think you will see 270 either. Don't be tempted to go with too big a turbo. Have you driven a car larger turbo'd diesel? You might not like it.

The reason for the smoke is that you are injecting for a large duration of crank rotation, to the point where the exhaust valve is open and fuel isn't getting burnt properly. The injectors are already working quite hard on your current map. How much smoke you can tolerate is personal, but I can tune it to whatever level you want

Rick

Hi Rick,

I messaged you before about this on FB i think Ive been in a car with the same engine that has a garrett 2260 turbo producing 290bhp dyno proven 330bhp on meth/water, was a bit sluggish but when boost kicked in it was mental, this was in a FWD which IMO is too much power and torque to handle poperly.

It was fine under normal load but under heavy throttle it smoked a LOT. Personally aslong as it doesnt smoke heavily around town and normal driving I don't mind. I have a choice of 230, 250 or 270 rated turbos. Whats the most BHP youve ever heard of/gotten out of one of these engines? It needs to be reliable as its my daily driver. Maybe I could go with the 250 turbo and tune to 240bhp? Potentially could be good compromise?

Cheers

 

[adamss24]

Best turbo for a daily driven car of your displacement would be a gtb2056vl or a gtb2060vklr as i've mentioned above. Both turbo will support 250Bhp reliably and will spool as soon as the turbo you already have stock on the car ! However they require fabrication as they are both water cooled and need custom downpipes, intakes and oil feed/drains. On top of the fabrication you will need also good map which i am sure Rick could provide...

 

[freezebox]

Best turbo for a daily driven car of your displacement would be a gtb2056vl or a gtb2060vklr as i've mentioned above. Both turbo will support 250Bhp reliably and will spool as soon as the turbo you already have stock on the car ! However they require fabrication as they are both water cooled and need custom downpipes, intakes and oil feed/drains. On top of the fabrication you will need also good map which i am sure Rick could provide...

Budget cant go that far for fabrication sadly thats the main reason why ive been looking at hybrids

 

[adamss24]

Where abouts are you based ? Drive down to London and i can fit a used gtb2056vl and build you a downpipe to mate with the rest of the exhaust. I will provide braided oil feed and drain pipes and can take care of the map as well unless you want Rick's map which i am happy to flash over ! I can take logs and send them his way so he can custom map as the hardware requires... Here's some of my previous work...

 

[Rick @ Unicorn Motor Dev.]

Hi Rick,

I messaged you before about this on FB i think Ive been in a car with the same engine that has a garrett 2260 turbo producing 290bhp dyno proven 330bhp on meth/water, was a bit sluggish but when boost kicked in it was mental, this was in a FWD which IMO is too much power and torque to handle poperly.

It was fine under normal load but under heavy throttle it smoked a LOT. Personally aslong as it doesnt smoke heavily around town and normal driving I don't mind. I have a choice of 230, 250 or 270 rated turbos. Whats the most BHP youve ever heard of/gotten out of one of these engines? It needs to be reliable as its my daily driver. Maybe I could go with the 250 turbo and tune to 240bhp? Potentially could be good compromise?

Cheers

The thing you need to bare in mind is that when they rate these turbos, that is the absolute perfect maximum, i've never actually seen a real world engine produce the rated power on a properly calibrated dyno...

Rick

 

[freezebox]

Where abouts are you based ? Drive down to London and i can fit a used gtb2056vl and build you a downpipe to mate with the rest of the exhaust. I will provide braided oil feed and drain pipes and can take care of the map as well unless you want Rick's map which i am happy to flash over ! I can take logs and send them his way so he can custom map as the hardware requires... Here's some of my previous work...View attachment 66592 View attachment 66592View attachment 66593 View attachment 66595

Pretty far away in Manchester, sent you a PM though.

 

[adamss24]

 

[adamss24]

 

[freezebox]

Did you get my PM mate?

 

[adamss24]

Hi, yes i did get your pm, i will work out a few prices and get back to you tomorrow !

 

[adamss24]

Allroad dual 3" full exhaust system...

 

[freezebox]

Allroad dual 3" full exhaust system...

Still waiting for ur reply m8

 

[Usmxn]

This seems exciting

 

[adamss24]

Most likely a ball bearing based 11 blade hybrid pal, considered a gtb 2260 but it requires so much more work and expense such as building a manifold etc. This way its just bolt on.

There are no ball bearing hybrids of your turbo, the only turbos that have a ball bearing cartridge are the gtb2260vklr and gtb2060vklr as fitted to the new mercedes 350 CDI Blue Efficiency...they are big money and require extensive fabrication in order to fit your car. Also they are water cooled and require an oil restrictor as they don't require as much oil as normal journal bearing turbos.
I could probably weld a flange to a manifold and mate it to a gtb2056vk/vl but i need your car to check clearances...doing a 2002 audi a3 for a forum member and i could not fit a gtb turbo... His car is a pd 100 so a healthy jump from 100 Bhp to 200 Bhp will be well felt !!! Not bad to double your power with a few bolt on mods and few days of fabrication...

 

[the obese penguin]

Ah if only I had the money to spend on some goodie. All my money seems to go on constantly preparing it.
Last Audi I'm ever buying that for sure.

 

[adamss24]

1.9 PD Tdi 100 Bhp turbo conversion: bv43a billet compressor, custom intake pipe, custom boost pipes, braided oil drain pipe, silicone bends, etc.

 

[bennyball]

Did you get anywhere with this?

 

[E5 FUL]

Very interested in this thread.

Running my pd140 at 203bhp and 380lbft. Just added new organic clutch and SMF. The SMF is loud as feck but I quite like it!

Currently got stock injectors and stock turbo, really not expecting the turbo to last that long but not sure which turbo to go for.
Ideally looking for around 250bhp, anyone know how much torque this will produce? As my new clutch is only rated to 400lbft...

 

[JamesS4cab]

What did you do to your 140 to get to 203bhp?