250+ hp Build thread

aming for 250+ whp hoping for 280 on motor and 320 on nitrous

PARTS:

GTB2260vk turbo , exhaust, and manifold from David at DriversFire
Race 520 injectors - Bora Parts
AVR 2.5 tdi pistons to increase displacement to 2.0- boraparts
rosten rods-bora parts
eurospec girdle- bora parts
4 bar map - RyanP
Pelloquin lsd- VwParts.com ( i wish i noticed boraparts had them before i bought mine because i could have saved some money)
108 mm flanges- vwtranny.com
arp head studs - nicktane
head porting - Whitebread performance
ebay intercooler ( 27x7x2.5)
rosten performance dual valve springs- rosten performance
colt stage 2 cam - steve glover
sb clutch rated to 650 ftlbs - steve glover
vr6 axles with lifetime warranty - autozone
and tuning from TDtuning

i will be building my own intake manifold

i will also personally be putting this all together and installing it.

BiG thanks to:
Aron at bora parts
TD tuning
Steve glover
David Frontz
Whitebread

for being patient with me, all my questions, and all my changed decisions.

i will be posting pictues and updates as i begin putting all the parts together. i'm still in the machining and parts gathering stage.

donor motor from a 2002 automatic ( 11mm pump woohoo)


donor tranny from a 2002


avr pistons look at the size of that bowl!!!!!


modifing the oil squirter relif on the AVR pistons ( its on the wrong side)

used a paint pen so i could write on it with a fine point sharpee and still see it.


marked the location using the squirter that is on the wrong side from anoter piston.



tracing the relif


Traced


covered up ready for surgery

done stock on left my hand cut with a dremel on the right


factory valve relif infront of my hand cut relif. pretty darn close not perfect but it clears the squirter with plenty of extra room






stock o2j donor tranny opened up


drilling rivets from ring gear


pelloquin installed


rosten rods on my modified pistons



Chip socketing
stock chips


stock chips removed


sockets in

girdle installed with proper gap set after some issues


measuring protrusion for proper head gasket fitment it came really close to the top of 2 hole so i went ahead and settled for a 3 hole just incase


head back from valve job after i got it back from porting THANKS MATT!


arpstuds Thanks NICK


Head on.


Timing set! i dont know how i did it before without the metalnerd tools they made it 1000 times easier



everything on except the injectors ( had to order some spacers for the brackets i cant seem to find them. ) and the acc belt , wiring harness


YES it is a 2.0 alh TDI

well this last weekend my machine was down for scheduled maintnance at work so i decided to go play on one of the old manual lathes heres what i came up with


shifter cable end links and cap


heres one of the end links that was on my new style shifter


i cut out the center leaving it rough so i had to press fit the end link in


here it is pressed in.


here one is installed

pictues 4

Good luck! I think you're really lacking in the fueling dept though... Based off your parts list I'm assuming you got a 10mm but will run an 11mm. IMO you need a 12mm. We haven't seen anyone with an 11mm on a 4 banger put out more than 250whp AFAIK. But, if you do run an 11 at first, I'm very interested in what you'll put down. Should be super smoke free!

--edit-- ditch them junk axles and go with some junk yard axles or Raxles...

Yes it will be an 11 for now. I will definantally be upgrading to a 12 when i put a completely moded head on. But that will be next summers project I will be getting it dynoed once i put 3000 miles on it for break in. So around october expect dyno numbers

I did get junkyard axles that were snapped for 15 each to use as cores for the lifetime warranty ones

Looking forward to the build. I will be doing something very similar.

uploaded more pictures!! if i get my turbo kit by tomorrow night i should have the car running with the new motor by thursday night

Bdpprocessors said:

Yes it will be an 11 for now. I will definantally be upgrading to a 12 when i put a completely moded head on. But that will be next summers project I will be getting it dynoed once i put 3000 miles on it for break in. So around october expect dyno numbers

I did get junkyard axles that were snapped for 15 each to use as cores for the lifetime warranty ones

Click to expand...

an original 11mm ip will flow more fuel than a 10mm pump with 12mm head...

JW

struikie said:

an original 11mm ip will flow more fuel than a 10mm pump with 12mm head...

JW

Click to expand...

but a 11 mm with a 12mm head will flow more than a 11 mm thats what i'll be doing. its just stock 11mm for now.

i was told that the 10mm with a 12mm head would flow just a tad more than a 11mm but it will also rev higher.

Bdpprocessors said:

but a 11 mm with a 12mm head will flow more than a 11 mm thats what i'll be doing. its just stock 11mm for now.

i was told that the 10mm with a 12mm head would flow just a tad more than a 11mm but it will also rev higher.

Click to expand...

that's not what we found
the 11mm ip + 12mm head will give enough fuel for your goals...

iirc turbo_johan has a 1.9tdi running a 14mm ip to 5750rpm :0
my 11mm ip is doing 5100rpm...

JW

struikie said:

that's not what we found
the 11mm ip + 12mm head will give enough fuel for your goals...

JW

Click to expand...

thats what i am planning on doing but i was just pointing out what ive read...

now where could i get one of these along with install instructions?

struikie said:

that's not what we found
the 11mm ip + 12mm head will give enough fuel for your goals...

iirc turbo_johan has a 1.9tdi running a 14mm ip to 5750rpm :0
my 11mm ip is doing 5100rpm...

JW

Click to expand...

Where did he get ahold of a 14mm

Bdpprocessors said:

Where did he get ahold of a 14mm

Click to expand...

That would likely be DSS

Those don't hold up very well at all. The 4bt would be better option since it can be built for high-ish rpm and flow even more than 14mm + VE pump

I think there is 13mm option for 4bt as well but you still lose the dynamic timing with the Bosch VE pumps so it may not be ideal for a daily driver

Bdpprocessors said:

thats what i am planning on doing but i was just pointing out what ive read...

now where could i get one of these along with install instructions?

Click to expand...

I had a DSS14 mm which goes wel on 2700 rpm max tractorpuller engine.
Tryed 1 14 mm in TDI and died within 5 runs on dyno..
We run 12 mm bosch with 11 mm camplate to 5700 rpm without problems for few years now.
Without 2 stroke oil adjust or stuff like that.

Johan

12mm with DE143 cam plate, lift pump, keystone mod and advance collar mod is where it's at.

Could you explain the advance collar mod? A quick search on this forum doesn't yield much, only your posts stating that it would be a good mod to perform.

Jon

It allows you to run more injection advance. Really only useful if the engine is going to run >5500 RPM.

Any hints on how to perform the mod or what it actually consists of?

In a nutshell (some people might get upset for giving this away), you machine the timing adjuster so that the maximum travel at its stop is at a greater advance angle (area labelled 4 and 5).


There's more to it than that and I'm sure even some things were withheld from what had been shown to me. I won't betray the request for confidence to give more details but this mod is familiar to any smart injection pump shop. Rocketchip Jeff can also probably do it with his RC6 or RC7 tune.

Thanks for the info!
Maybe some day I'll look into this further.

Jon

Meister how would this mod hold up with a 3.5mm cam plate and 12mm head on my spare 10mm.....would it provide the revs I need beyond the 3800rpm previously discussed?

Also how would a standard 11mm pump benefit from this mod?

The pump case is physically the same so no reason why there should be a problem. Turbo_johan above has successfully run a 12mm pump head and 11mm cam plate to 5700 RPM for a few years now. Just have to make sure the right springs and delivery valves are carried over. The best results are a Frankenstein of parts that are best left to an expert.

very cool tread will be following

I am also running 12mm + DE143 in 11mm case. Good for 5.5K+ rpm but no need to go higher

Renault camplate only worked briefly. Doesn't hold up to rpm

4bt seems like best way to go if you want extreme fueling

TDIMeister said:

The pump case is physically the same so no reason why there should be a problem. Turbo_johan above has successfully run a 12mm pump head and 11mm cam plate to 5700 RPM for a few years now. Just have to make sure the right springs and delivery valves are carried over. The best results are a Frankenstein of parts that are best left to an expert.

Click to expand...

Why change the delivery valves?

Found this thread helpful....http://forums.tdiclub.com/showthread.php?t=238872

TDIMeister said:

In a nutshell (some people might get upset for giving this away), you machine the timing adjuster so that the maximum travel at its stop is at a greater advance angle (area labelled 4 and 5).

There's more to it than that and I'm sure even some things were withheld from what had been shown to me. I won't betray the request for confidence to give more details but this mod is familiar to any smart injection pump shop. Rocketchip Jeff can also probably do it with his RC6 or RC7 tune.

Click to expand...

Would this set-up be reliable for a daily driver, or is this just "track stuff"?

Thanks,

df

loudspl said:

I am also running 12mm + DE143 in 11mm case. Good for 5.5K+ rpm but no need to go higher

Renault camplate only worked briefly. Doesn't hold up to rpm

4bt seems like best way to go if you want extreme fueling

Click to expand...

What 4bt pump does these12mm heads come off of. I know there are many versions of that pump got any part numbers for 4bt pump.

VWDAVID said:

What 4bt pump does these12mm heads come off of. I know there are many versions of that pump got any part numbers for 4bt pump.

Click to expand...

I think the head off the B-series inline 4 Cummins 3.9L will be plug-n-play

Bosch part # 0 460 424 045