WANTED: Bosio race 683 nozzles to fit v6 tdi engines

2 piston original afb pump
130% nozzles.
Yes, it smokes with 55...60mg
In 3rd Gear spool begins around 3500...4000rpm.

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Very clean install !

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Looks quite small for being gta40v series.

After a long period of inactivity on the tdi front I finally got back to experimenting with my 2.5 ake.
A few months ago I installed the water/methanol injection in order to get the EGT down.
EGT are rather problematic with the bosio R683 and almost 30psi of boost, rising quickly to 800°C at WOT. (I know my 2052 is going to blow up )
The water injection helps, I see about a 70 degree drop when activated. When adding a 20/100 alcohol to the mix there is a noticable power increase but the cooling effect is less.
The bigger gt2559v is about to get installed, the plumbing is nearly ready.

Before the remap, R683 and water injection it got 192hp and 412Nm on the dyno, only mod then was ported heads.
The last runs with the mods and 2052 @ 2 bar where very promising, a A6 3.0 tdi with 240hp didn't stand a chance.

With the water cooled 2559 and 3' downpipe I hope to get EGT and EMP at a safe level, we'll see.

Very interested in the results of the vklr turbo Adamss24

Has anyone looked into modding the passat 240hp biturbo headbolts to fit the 2.5 v6 tdi ?

Looking at the gt2559v today made me wonder about future upgrades, the big compressor housing just shouts 'give me a bigger wheel' something like 66mm.
Did anyone try this already ?

Do you guys still run the shutoff butterfly in the intake ? That piece of the intake is a real bottleneck, the air that passes the lower half just hits a wall (where the EGR is fed into the intake tract) and will probably disturb the flow in the upper half. I just cut out that chunk and welded the hole in the bottem shut, using a bit of epoxy on the inside to make a smooth transition.

I had an gt2559v with 62/65 compressor. Ran great on my 2.5 tdi 5 cylinder.

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How much turbo pressure did you run with the modified 2559 ? I would like to run 2 -2,2 bar.
Would a billet compressor wheel be preferrable over a normal cast wheel ?

tbh would just use a 2260 vrk or vklr. should do 350-360hp with a 70/50 wheel. maybe more with bigger turbine.

50/70 wheel is wayy too big for 2.5TDI + stock 2260vk turbine. That wheel can do over 400bhp on that engine size. I would use 47mm billet wheel with original turbine.

Yes. 47.9/63 comp is way good for 350hp. I would still recommend to use bigger turbine shaft. Stock 2260 is good for 320hp on these engines with good 15.5-16afr

A vklr would be nice, however the plumbing would not be so easy I think.
For now I will continue with the 2559 since I have al the pipe work 90% ready. When that setup works well I will get a bigger wheel. Low end is not such an issue, with the 2052 I already had insane boost levels at 1500rpm, the dual mass flywheel shaked like hell even at part throttle <2600 rpm. So having boost come in at higher rpm would be better.

Still thinking of converting a dmf to smf, even if that means shortening the gearbox life.

Ditch the gt2559v and just fit a gtb2260vk, much more linear boost and plenty top end- 300 Bhp on stock hardware... gtb2260vklr fits pretty well in an allroad engine bay, the fuel cooler provide an easy way to tee into the cooling system...

search for a 2260vrk from audi 272hp prototype. they sometimes pop up on ebay germany/poland. externally they look like 2260vzk with integrated Y piece. they have slightly bigger comp inducer than 2260vk.

Is that a vklr in the pictures or a vk ?
I thought the vklr had the exhaust manifold cast to their exhaust housing (1 piece), so to adapt them to you had to cut them and weld on a flange ?

Where is the fuel cooler located exactly in an allroad ?

Thx

in the picture is a VK. the vzk/vrk has integrated Y piece. which I though would not be so bad to adapt as it has to come on a V6 engine. basically one woul need to extend the pipes coming from each bank and make a support which carris the CHRA and has oil feed/return

Once you make exhaust manifolds and link pipes is easy to install vzk. I wouldnt leave any stock manifolds when having lots of power. We have seen manifolds fail only chiptuned card also. Only nasty thing is indeed make oil in/out lets but once you have flange there is really not that big issue to make lines. We have made full gtb2260vzk with Electronic controller and works nice even the ecu isnt even changed.

nice. did u use benz/volvo actuator that accepts PWM? or did u manage to build a controller with H bridge to control the stock vzk actuator?

It has small adapter/controller plugged parallel to n75. Parallel to n75 worked better than using just a resistor. Forgot to take pics.

ok but its a DC motor with sensor actuator (stock audi-dumb one) and not smart actuator from benz/volvo with built in motor control? do you have link for the contoller?

Rub87 said:

ok but its a DC motor with sensor actuator (stock audi-dumb one) and not smart actuator from benz/volvo with built in motor control? do you have link for the contoller?

Click to expand...

It gets feedback from actuator and compares it to requested.
http://dmn.kuulalaakeri.org/HellaVNTServo/

Another good thing is that it is really flexible and therefore fits basically any msa/edc15 ecu with n75 or even for older 3.0tdi engines to upgrade garrett turbo unit.


And I had some low quality photos from the install at http://evvk.1g.fi/kuvat/Diudi/booster/hella/

Dyno result from this morning, cpc nozzles +66%

Well there Ben, switched to other nozzles since the last run I see.
I was curious on the gains you had, but the link to the previous dyno measurement indicates an empty folder. Can you re-upload that run?
How does the car feel as a daily driver, is the clutch assembly holding on?
Could you list all the modifications that were made?
Thanks!

Have reloaded the photo now.
It feels great now, the best it's been in fact, clutch is fine, some flywheel judder at low revs, but I just change down, a bit smokey on full throttle.
adamss24 hybrid 2260 turbo (billet)
adamss24 mapping
adamss24 3" downpipe
stock injectors, cpc doktorec nozzles +66%
egr delete
diffas exhaust manifolds and link pipes

Hi Ben, unfortunately there is no photo in the drop box, what was the end result Bhp and Nm ? I do hope you're pleased with it !

Ben also has: alloy boost pipes and 4 Bar Map sensor. The clutch is a Sachs SRE jobbie with stock pressure plate...

@Ben - try to post the direct links to photos (ones that end in ".jpg"). You are somehow fixing one link while damaging the other

He's figures were 280HP@fly and from what I remember 580Nm, with a much linear torque curve developing 300Nm @2000rpm and ~475Nm @ 4400.

jobbie = clutch disc?
Could the setup perform better if fitted with SRE sintetic disc + SRE pressure plate?

Meant to say Sachs SRE organic clutch and stock flywheel. 280 Bhp and 580Nm is what I was expecting to be honest, the turbo can do 2.4 Bar of boost comfortably and has acceptable EGT. I had 300 Bhp with same turbine but 65mm compressor also at 2.4 Bar of boost ! That was a wicked car to drive, so much torque...