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TDI Power Enhancements Discussions about increasing the power of your TDI engine. i.e. chips, injectors, powerboxes, clutches, etc. Handling, suspensions, wheels, type discussion should be put into the "Upgrades (non TDI Engine related)" forum. Non TDI vehicle related postings will be moved or removed. Please note the Performance Disclaimer.

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Old November 1st, 2013, 12:32   #1
JFettig
 
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Default CR140 Stage 3

I have been running Stage 3 on my CR140 for a couple months now, still making minor tweaks. I did a bunch of research and found everything I needed, its pretty simple easily as "bolt on" as a VNT17 is to a ALH or BEW.

Turbo: 03L 253 016 G

Turbo Inlet Pipe: 3C0 129 654 AJ or 3C0 129 654 P

Turbo inlet to turbo elbow: 3C0 129 635

EGT probe is too short so you need to make a spacer, .43-.45" OD, .285" ID .1" thick. Maybe the CR170 probe would work, which is straight.

Another option for a turbo is this:
Turbo: 03L 253 019 M - it has the older style flat faced outlet

All of these parts are available from Ebay UK or various vendors in Europe

Other than the EGR, this is a bolt on turbo upgrade. The EGR port on the manifold is on the opposite side, so it will have to be deleted. These turbos don't accommodate the LP EGR so that will have to also be deleted. I can't imagine that anyone installing this turbo will keep them. The DPF will still bolt up just fine or other available downpipes will also bolt up. There is another option to make the EGRs work, swap center section into the CR140 exhaust housing and bore the compressor cover for the CR170 wheel, a competent machine shop should be able to handle that. I know of 2 local shops that do it already(to other turbos). I haven't verified that the CR170 turbine fits in the CR140 exhaust housing, a PD170 turbine does however.

I don't have much for install pictures, it all pretty much goes in the same as it comes out, just like replacing a stock turbo. The DPF comes out, turbo comes out the bottom, new turbo goes in the bottom, overall not very difficult. To swap the turbo, the DPF must come out, oil return line, oil feed line, turbo outlet, all disconnected along with sensors. The passenger side axle must come out to do this. Pull all 8 exhaust nuts from the turbo to head studs, pull turbo off of the head and drop it down through the opening between the sub frame and the oil pan. new turbo goes back in reverse.

Two turbos side by side, notice the larger inducer on the CR170 turbo


Here is a picture of the EGT probe spacer:
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DIY injector calibration http://forums.tdiclub.com/showthread.php?t=383324

Last edited by JFettig; March 3rd, 2014 at 19:42.
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Old November 1st, 2013, 12:32   #2
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I'll be posting dyno sheets once I get on the dyno again, so far I'm up to 180whp/340ft-lbs 100% smoke free, stock like EGTs(doesn't even hit the EGT limits) and 196whp/340ft-lbs with very light smoke. I'm expecting around 200-205whp on a dynojet and 350-360ft-lbs, maybe more with similar smoke levels to Stage 2. Still making 130hp at 5000rpm
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DIY injector calibration http://forums.tdiclub.com/showthread.php?t=383324

Last edited by JFettig; November 1st, 2013 at 20:26.
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Old November 1st, 2013, 12:32   #3
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Replacement gaskets:

8x copper pinch nuts: N90200201

Oil return line gasket: 03L145757Q

2x oil return line o-rings: N90715601

Oil return block copper seals - unknown part number, I didn't replace

EGR manifold gasket: 038131547A

EGR intake gasket: 069131547D

Exhaust manifold gasket: 03L253039B

Downpipe gasket: 1K0253115T
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2009 JSW Stage 3 196whp so far
DIY injector calibration http://forums.tdiclub.com/showthread.php?t=383324

Last edited by JFettig; March 13th, 2014 at 16:35.
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Old November 1st, 2013, 13:18   #4
Paulinski
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Very coo. Thanks for the info. Is there an option of exhaust header upgrade similar to Darkside Kit?
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Old November 1st, 2013, 14:10   #5
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Very nice!
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Waiting for the DPF to fill here while using 2SO & RP HPS 5W-30 oil.

Last edited by steve05ram360; November 1st, 2013 at 14:51.
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Old November 1st, 2013, 14:33   #6
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Quote:
Originally Posted by Paulinski View Post
Very coo. Thanks for the info. Is there an option of exhaust header upgrade similar to Darkside Kit?
The whole idea of using a CR170 turbo is as a low cost alternative to the custom fabricated Darkside kit.
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Old November 1st, 2013, 14:59   #7
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Nice!
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Old November 1st, 2013, 16:16   #8
BKmetz
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Some clarification: at this point in time JFettig is not planning to sell his set-up and asked our permission to have this thread.

This is an informational/technical/developmental thread only, which is allowed.

If at some future point in time he decides to market these parts, he will start a new thread in the vendors forum.

No need to report this thread as a viloation of vendor rules.

Thank you.

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Old November 1st, 2013, 16:43   #9
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Thank you thank you thank you for sharing. How has the tuning been going?
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Old November 1st, 2013, 19:47   #10
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Tuning has been going well, we could have called it done a long time ago but we're making minor tweaks to make it better and better. I haven't done more than drive the car for the past week, maybe I'll spend some time on it next week if I have time.
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1998 B5 Passat TDI Compound Turbos
2009 JSW Stage 3 196whp so far
DIY injector calibration http://forums.tdiclub.com/showthread.php?t=383324

Last edited by JFettig; November 23rd, 2013 at 08:25.
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Old November 1st, 2013, 20:07   #11
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Nice! Glad someone finally fit it up! I bought one of these three years ago and haven't had a chance to fit it up. finally skipped right over it and went with a custom setup to see what I could do with the car.

John, how did you clutch hold up? Do you have torque limited or a dsg? Manual owners may want to do a clutch upgrade if going over stage 2.. Had a few that were getting the dreaded dual flywheel chatter.
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Old November 1st, 2013, 20:10   #12
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It should be pretty obvious to anyone reading this thread that JFettig is providing this community with a huge amount of knowledge that would be a valuable asset to anyone thinking about a budget turbo upgrade. All the part numbers needed, which tuner has a good base map ready to go, heck, even dimensions on how to machine the only part you can't buy off the shelf, dyno sheets to back it up. How-to thread don't come any higher quality than this one.
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Old November 1st, 2013, 20:12   #13
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Awesome man!!!
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Old November 1st, 2013, 20:20   #14
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Thanks guys,

Kyle - stock clutch is holding pretty well so far however I don't think the DMF is happy. It is starting to clunk on and off power. I need to check my dogbone bushing to make sure that isn't the problem. I have a Stage 3 endurance clutch+FW to go in soon. Its making 340ft-lbs, there's more to go too. On tip in lambda is around 1.2 right now, with it closer to 1 or even below 1 it'll make a lot more torque!

Lambda = 1.02 makes 180whp
Lambda = 1.0 makes 190whp
Lambda = 0.98 is what I'm running right now but haven't gotten it on the dyno.
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2009 JSW Stage 3 196whp so far
DIY injector calibration http://forums.tdiclub.com/showthread.php?t=383324
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Old November 1st, 2013, 20:31   #15
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great to hear! FYI for those looking for an upgrade and still keep oem like emissions you should be able to use the 2005-2007 EGR cooler and pipes to fit up to this for the high pressure EGR side. You will then need to make a pipe piece ` 3" long, 3/4"D with a 10mm 1.5 corse thread nut welded to the side and a clearance hole through it. You will then take the LP egr cooler assembly temp sensor and put this in it and connect the coolant lines up to the system. You still need to figure out how to handle the servo and feedback for the lp egr setup. I am hoping in the future tuners can remove it from the tunes and pass the egr obd tests because you still have a HP egr.

With luck, you can do the above, with oem downpipe and this turbo for a clean 170whp setup...
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