Audi A6 Avant 2.5 V6 TDI Quattro

[blackquattro]

Ofcourse the M5 or M6 studs that hold the plates down (and preload them) could break or be ripped out of the alu heads when 2 parallell plates are used, I'll give it a try on a spare head next week.

 

[blackquattro]

My flywheel is getting really bad, but I fear that replacing it with a new DMF will not solve the harsch vibrations I always had between 1800 and 2500rpm. However the car had already 180000km on it when I bought it, so it could have been already on its way out when i started driving it. What do you 2,5 tdi v6 tuning gurus think ? Would a new DMF and Sachs SRE solve my problems or should I weld the DMF and use a sprung cluch disc in combination with the Sachs HD pressure plate ?
There is a SMF conversion from Valeo for the 2,5 v6 Tdi, but apparently it will only fit the 150hp engines and not the 163 and 180hp engines. I don't know why, maybe bolt pattern ?

 

[adamss24]

My flywheel is getting really bad, but I fear that replacing it with a new DMF will not solve the harsch vibrations I always had between 1800 and 2500rpm. However the car had already 180000km on it when I bought it, so it could have been already on its way out when i started driving it. What do you 2,5 tdi v6 tuning gurus think ? Would a new DMF and Sachs SRE solve my problems or should I weld the DMF and use a sprung cluch disc in combination with the Sachs HD pressure plate ?
There is a SMF conversion from Valeo for the 2,5 v6 Tdi, but apparently it will only fit the 150hp engines and not the 163 and 180hp engines. I don't know why, maybe bolt pattern ?

I have just rebuilt a BDH engine with ported heads and solid camshafts, i will use a rs4 uprated clutch from Sachs SRE and a Sachs DMF. I was thinking of using a b5 rs4 solid flywheel but i don't really thing SMF is the answer and it will damage the gearbox sooner or later ! My other b6 audi a4 1.9tdi did munch the syncros in the gearbox in about 3000 miles with a Southbend clutch and SM flywheel !
As per the Valeo SMF conversion, they do fit the v6, the crank is the same, however the b6 and allroad/a6 uses the LUK self adjusting clutches. The Valeo is usin a vr6 clutch plate and organic disc, not man enough for the v6 torque...

 

[doktorec]

You will not damage that gearbox.It's undestroyable by this 2.5tdi.The gearbox is 01E and is very strong.Google it.It can hold nearly 1000nm.They use this gearbox housing to make dogbox gearboxes.

 

[LongJohn]

I guess torque doesn't brake the tranny but what about the diesel engines vibrations with less damping from SMF?

Other concern is the torsen that backs up tranny. What I know that isn't that solid that 01E tranny itself is if you start teasing it on dry asfalt.

I did FW + clutch job a year ago. Went for stock DMF with SRE clutch with stock clutchplate. Decisions decisions...

 

[Scott_DeWitt]

I guess torque doesn't brake the tranny but what about the diesel engines vibrations with less damping from SMF?

Other concern is the torsen that backs up tranny. What I know that isn't that solid that 01E tranny itself is if you start teasing it on dry asfalt.

I did FW + clutch job a year ago. Went for stock DMF with SRE clutch with stock clutchplate. Decisions decisions...

The 01E is extremely strong, probably one of the strongest VAG boxes available.

With the 1.9 and SMF, the synchro rings in the gearboxes break. Although with a 6 cylinder it's smoother engine and should have less vibration.

 

[adamss24]

The 01E is extremely strong, probably one of the strongest VAG boxes available.

With the 1.9 and SMF, the synchro rings in the gearboxes break. Although with a 6 cylinder it's smoother engine and should have less vibration.

I know someone broke a DQS 01E gearbox 3 times with Sachs SRE clutch and 1Z solid flywheel, it was on a 250Bhp pd130... Syncro's gave up the gost in each circumstance ! He ended up breaking the car for parts, was FWD though !
I did not see a quattro 01E broken, i don't do launches but i drive my a6 really hard every time i get the chance...

 

[adamss24]

Scott, any news with them nozzles from Doctorek ?? Did you get them fitted in the end ? Working on a BDH engine with ported heads and solid cams to fit on my old a6, still un-decided if to use the race 683 nozzles or go for the 125% nozzles from doctorek ! Also using a Sachs SRE clutch and standard DMF...

 

[diffas]

You can broke everything with doing something unhealthy. If you look closely almost all(allroad boxes have shorter gears) 01E boxes use same first 3 gears and difference is made with differential and different 4-6 gearing. Old (before 96) 01E boxes did have weaker 1st gear and got broke when having past 800hp/nm with quattro launches.

 

[adamss24]

New turbo for my other allroad tdi: gt22 turbine and 66mm turbine with a 50mm inducer and twin stagered gap seals ! Still tweaking the actuator rod for it but it's not any lagier than the original gt2052v that was in there but it has more midrange. Getting it tuned today so hopefully the clutch holds together...if not the Loba +15% rs4 Sachs SRE will get in !







From left to right: gt1749vb, gtb2056vl, gtb2260vk and DMB wheel with extended tip technology !

 

[doktorec]

http://www.youtube.com/watch?v=oHnFTf_o6xw midnight tests

 

[LongJohn]

Is that With those +125 nozzles and +++2 Bar boost?

 

[adamss24]

http://www.youtube.com/watch?v=oHnFTf_o6xw midnight tests

That's well fast ! Well done mate, i keep telling people that's so much potential in the 2.5 tdi engine yet everyone's seeing-it as a pain in the proverbial !

 

[doktorec]

That is my business partner's car.It has the biggest nozzles and the boost is 2.7bar.
Stock cooler.The car will have custom intake manifold soon and after that a dyno.

 

[LongJohn]

That is my business partner's car.It has the biggest nozzles and the boost is 2.7bar.
Stock cooler.The car will have custom intake manifold soon and after that a dyno.

What other mods?

Where do you see 2,5TDI limits fully modded? Intake, IM, ported heads, cams, valves, turbo, DP, exhaust system, nozzles, IC...

 

[doktorec]

What other mods?

Where do you see 2,5TDI limits fully modded? Intake, IM, ported heads, cams, valves, turbo, DP, exhaust system, nozzles, IC...

Fully moded IMO is : Heavy ported heads(or heads from another TDI).More aggressive cams.
Twin gtb1749V(Gtb1752V hybrid).Lift pump,big cooler,Custom exhaust and intake manifolds(tubolar)Lowering the CR by grinding the piston.
Big nozzles,Modifying the pump internal pressure.
Rev limiter 6000rpm.(this is because it's a 6 cil engine and the pistons have enouhg time to cool).
I think 500-550hp and 800nm is good.Maybe the gasket will not hold this so maybe ARP headbolts.

 

[blackquattro]

The exhaust manifolds are far from ideal, also prone to disintegrate leaving the turbo to chew up the pieces of debris. I am thinking of welding together some new ones using stainless 42mm 90 degree elbows. Right before the stock piping enters the collector on which the turbo sits the outside diameter reduces to about 36mm, too small to my liking.

2,7 bar boost pressure ??? What turbo is he running ? I am very interested to know the dyno results from this engine.
You

 

[adamss24]

The exhaust manifolds are far from ideal, also prone to disintegrate leaving the turbo to chew up the pieces of debris. I am thinking of welding together some new ones using stainless 42mm 90 degree elbows. Right before the stock piping enters the collector on which the turbo sits the outside diameter reduces to about 36mm, too small to my liking.

Put me down for a few sets if you ever get the manifolds fabricated for a reasonable price, otherwise i will have to ask my dad to weld a pair or two for me ! He has over 40 years experience as a panel beater/welder...
I tried using 3.0Tdi exhaust manifolds with a GTB2260vk but they required minor modding and extra bracing for the turbo. In the end used the AKE/t25 style collector manifold and just built adapter plates...looks stock.

 

[doktorec]

The exhaust manifolds are far from ideal, also prone to disintegrate leaving the turbo to chew up the pieces of debris. I am thinking of welding together some new ones using stainless 42mm 90 degree elbows. Right before the stock piping enters the collector on which the turbo sits the outside diameter reduces to about 36mm, too small to my liking.

2,7 bar boost pressure ??? What turbo is he running ? I am very interested to know the dyno results from this engine.
You

Turbo is GTB2266V and is not operated by ECU.It is operated manualy.It has no spikes in boost.We don't have any problems with exhaust manifolds for now.

 

[Underground75]

i drive now +75% Nozzles and gtb2260vk(1,95bar) in my AKE
result is 287hp and 580Nm

Is this setup drivable for a daily driver?
How is the fuel consumption while cruising?

 

[LongJohn]

i drive now +75% Nozzles and gtb2260vk(1,95bar) in my AKE
result is 287hp and 580Nm

You mensioned Fmic. What fmic do You use and is it installed into Stock bumper?

 

[adamss24]

I have just swapped the engine in the a6, it's fjtwelve's old audi a6 on which i have rebuilt the engine after crankshaft pulley broke the keyway !
Anyway, the new engine is a BDH 180 Bhp block with BDG heads, lower compression head gaskets, heavily ported and fitted with new, solid genuine camshafts. To be honest i am a bit disappointed with the swap, the new engine does not pull as hard as the old one-the new cams does not have that aggressive profile anymore- to keep emissions low ! I was building this lump for a while and got a good offer on the old engine so i could not pass on it ! The main reason for the swap was the clutch slip limiting the boost amount i could ask in the tune-had to de-tune it just to make it cope. On inspection the grease monkeys that fitted the clutch did not reset the pressure plate self adjusting mechanism hence the clutch not grabbing properly ! The old clutch done a couple of thousands miles if that so there's plenty life left in it-will use it on another car i have at some point as it's a waste not to.
First impressions with the Sachs SRE clutch is very, very light pedal, i was quite impressed with the bite, it's a little more grabby on take off-needs slight more revs for a smooth engagement but quite ok for now ! I have done a few logs so not a hint of clutch slip yet ! Does anyone knows if the Sachs SRE need bedding in ? Thanks in advance folks and keep modifying them old engines !

 

[adamss24]

You mensioned Fmic. What fmic do You use and is it installed into Stock bumper?

The fmic fitted to a6 allroad v6 tdi from 2000-2001 is made entirely out of aluminium and can take silly amounts of boost ! Blown many boost hoses but the intercooler is holding fine !

 

[adamss24]

Is this setup drivable for a daily driver?
How is the fuel consumption while cruising?

Very, very driveable ! You have so much torque at your disposal, your foot itches to press on the loud pedal ! Fuel consumption is also good for performance, i do 450 miles on a tank in town with a heavy foot and dirty tune ! I have seen as much as 650 miles on a tank with a mixture of town and motorway drive at speeds of +100Mph !

 

[LongJohn]

The fmic fitted to a6 allroad v6 tdi from 2000-2001 is made entirely out of aluminium and can take silly amounts of boost ! Blown many boost hoses but the intercooler is holding fine !

And it fits to B6 bumper?

 

[Underground75]

Very, very driveable ! You have so much torque at your disposal, your foot itches to press on the loud pedal ! Fuel consumption is also good for performance, i do 450 miles on a tank in town with a heavy foot and dirty tune ! I have seen as much as 650 miles on a tank with a mixture of town and motorway drive at speeds of +100Mph !

Now that's interesting. Next year I want to buy me a VW Passat Variant 2.5TDI 4Motion (180bhp) and want to give it some more power but was afraid it whould consume more diesel. Looking at this it looks like I can save diesel with my daily driving (60 to 75 MPH) with once or twice a week pulling it to 80 or 86 MPH with about a distance of 86 to 130 miles.

Seems to be (theoretical) even more economical than standard. I'm also planning a Webasto heater.

 

[audiake]

Hi all.
(sorry for my english)
I have 2001 A6 Q 2,5 tdi AKE 180hp. I need replacing the nozzles. I read here (in other topic) many talks abut the tweeking, and some people mentioned Bosio and other. My question:
I dont want tweeking (becouse my car have Auto transmission), i want only replacing the nozzles some similar like the stock. (i can't buy the original Bosh, that's horribile).
Can You recommending any parts?

 

[adamss24]

Hi all.
(sorry for my english)
I have 2001 A6 Q 2,5 tdi AKE 180hp. I need replacing the nozzles. I read here (in other topic) many talks abut the tweeking, and some people mentioned Bosio and other. My question:
I dont want tweeking (becouse my car have Auto transmission), i want only replacing the nozzles some similar like the stock. (i can't buy the original Bosh, that's horribile).
Can You recommending any parts?

Go on ebay and buy a used set of injectors, i would suggest allroad AKE or BAU...if you need the car stock then there's no need to upgrade nozzles, good replacements will do fine !

One thing to note, the needle lift injector has a square plug on your car and the later have a oval plug, just buy a plug from the dealer and get that fitted- do not cut the injector to fit the harness !

 

[quattrosens]

Hi all.
(sorry for my english)
I have 2001 A6 Q 2,5 tdi AKE 180hp. I need replacing the nozzles. I read here (in other topic) many talks abut the tweeking, and some people mentioned Bosio and other. My question:
I dont want tweeking (becouse my car have Auto transmission), i want only replacing the nozzles some similar like the stock. (i can't buy the original Bosh, that's horribile).
Can You recommending any parts?

Original BOSCH nozzles DSLA142P1191 (Audi BDH engine) work fine for 250hp

 

[doktorec]

Original BOSCH nozzles DSLA142P1191 (Audi BDH engine) work fine for 250hp

There is no stock V6 nozzle that can go over 210hp.They are too small.If you tweak the pump Yes.But stock BDH nozzle can go to 200-205hp and that is MAX.