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Darkside Developments CR140 GTB2260 turbo kit

bhutchins

Veteran Member
Joined
Feb 7, 2011
Location
SW Portland OR
TDI
Jetta TDiCup, 02Q built Sept 2010
Getting started / baseline:

I recieved the kit next day by DHL!
I volunteered to fit the kit to my US CR140, I guess the US had the CR cars before the UK.
A lot of work has been done by Storx too here
http://forums.tdiclub.com/showthread.php?t=357716
Here's Ryan's early mock up:

Note: the compressor outlet has been cut and rotated, Storx did this too, so it will fit close to the IC pipe

this is also the same turbo O.C.TDI http://forums.tdiclub.com/showthread.php?t=268968
used on his 2004 jetta with 248whp/433wtq

the kit included everything shown. the CR actuator, gaskets, bolt, modified turbo, header, oil feed and drian lines.

the header is made out of pipe, not tubing, so it is very durable.

this is a prototype, and it's fitment will be used to improve future kits.

I dyno'd the car with Performance-diesel downpipe 2-1/2" turbo back exhaust w/ cat and malone stage 2 tune and made 164 whp and ~285 wtq


the kit looks like the other dark side kits, with all the parts and gaskets below
with Audi GTB2260VK Turbo GS4 059 145 722 S

picture updated 10/29/2012

In preparation, I already installed:
Euro S3 IC
SouthBend Stage 3 Endurance Clutch
Pelequin Limited Slip Diff
 
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bhutchins

Veteran Member
Joined
Feb 7, 2011
Location
SW Portland OR
TDI
Jetta TDiCup, 02Q built Sept 2010
Getting the EGR system out of the way is a lot of work. Anyone considering a turbo upgrade may want to go ahead and get the EGR removal kit for "off road use only" of coarse. I have Ryan's kit here The Anti Shudder Valve (ASV) is shown right below.



this is what it replaces.... I dont want that gunk in my intake!


you will have to drain the coolant (aka anti-freeze) to remove the EGR cooler. the stock fluid is known as G12

As much as I tried, I could not get the EGR cooler out with the subframe still in, so turn to the steering rack replacement section of the Bently's manual

Remove the subframe: Remove the 4-13mm (1/2") bolts, the 16mm (5/8") and the 18mm (no equal) and the subframe will drop off, which allowed for the removal of the EGR cooler.

Unbolt the axle from the trans. this will really make for a lot of room. alternately you can remove the pass. tie rod end bold, then unscrew it with the hex in the middle, and unbolt the swaybar link and push them rearward
 
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bhutchins

Veteran Member
Joined
Feb 7, 2011
Location
SW Portland OR
TDI
Jetta TDiCup, 02Q built Sept 2010
the turbo's out, comparing the two...




Going in:
IT FITS!!!!
I had to unbolt the axle from the trans to make room, but it went in relatively easy


Its close to the firewall, and the hood seal, but there's room for movement. I taped thw wires in foil backed mastic "foilmastic" and flipped the firewall wire hold down upside down to raise them up


per Storx:
When you go to install the subframe center back, trace the bolt on passenger side that bolts to steering electric motor assembly and put that bolt in first on Center section
The bolt is the rear small one on passenger side
make sure the alignment pins are in their holes on drivers side before you install the rest of the bolts


Bentleys list bolt torque to 50Nm (37 ft-lb) + 1/4 turn (90 degrees) - Always Replace

the bolts to the sway bar bushings are 17 ft-lb + 1/4 turn, part numbers are either
10x76mm bolt: N 105 797 02 or
8x75mm bolt: N 910 734 01
 
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bhutchins

Veteran Member
Joined
Feb 7, 2011
Location
SW Portland OR
TDI
Jetta TDiCup, 02Q built Sept 2010
the plastic IC pipes are restrictive, so had some sent from RyanP "across the pond"
 
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bhutchins

Veteran Member
Joined
Feb 7, 2011
Location
SW Portland OR
TDI
Jetta TDiCup, 02Q built Sept 2010
234 WHP / 404 WTQ, uncorrected, on same dyno
stock fueling

Video
http://youtu.be/w27EMe1LGSM
no smoke until WOT

Click for full size pdf

for comparison
2014 5.0 mustang 420 HP @ 6500 -16% = 352 HP / 390 FT-LB TQ @ 4250 -16% = 390 ft-lb
2013 370Z 332 HP @ 7000 - 16% = 279 HP / 270 ft-lb @ 5200 - 16% = 227 ft-lb
2013 Nissan GT-R 545HP - 16% = 458 HP / 463 ft-lb @ 3200 - 16% = 389 ft-lb
 
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NewTdi

Top Post Dawg
Joined
Jan 15, 2004
Location
NorCal
TDI
2003 Bora, Reflex Silver
Reserved for post 6!

This looks like a super look project!
 

NewTdi

Top Post Dawg
Joined
Jan 15, 2004
Location
NorCal
TDI
2003 Bora, Reflex Silver
Justin, you have eyes in too many places! Thanks for the big turbo install; car runs great!
 

bhutchins

Veteran Member
Joined
Feb 7, 2011
Location
SW Portland OR
TDI
Jetta TDiCup, 02Q built Sept 2010
Eyes on this
if your just going to sit there and watch, you may as well lend a hand :)
it goes up on the ramps tomorrow

Aren't you running the 2260 also?

Actually I will need your expertise soon. I had bought that short block off the other Justin, I'm going to ceramic coat the pistons, and I already have the Rosten rods.
 
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oldpoopie

Vendor
Joined
May 14, 2001
Location
Portland Oregon
TDI
2001 golf gl, 2006 jetta, 1981 ALH swapped rabbit pickup, 1998 beetle
Indeed I am. Also building up a pd to swap to, and will be using a gtb2260 water cooled
 

bhutchins

Veteran Member
Joined
Feb 7, 2011
Location
SW Portland OR
TDI
Jetta TDiCup, 02Q built Sept 2010
updated the kit picture in post 1

Injector socket (T40055) works great for removing the stock turbo oil feed line

man is that EGR stuff hard to get off. the EGR filter back bolt is hard to get to. the turbo oil drain line is in the way, my 3/8 drive socket might work if I had a 2" extension (4" is too long) and I cant get a standard wrench on it either. off to the harware store.

Update: the 1" extension worked perfect
 
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storx

Veteran Member
Joined
Jan 16, 2006
Location
Earth!!
TDI
2009 Jetta CR140, 2010 Corvette Z06
updated the kit picture in post 1

Injector socket (T40055?) works great for removing the stock turbo oil feed line

man is that EGR stuff hard to get off. the EGR filter back bolt is hard to get to. the turbo oil drain line is in the way, my 3/8 drive socket might work if I had a 2" extension (4" is too long) and I cant get a standard wrench on it either. off to the harware store.
I will have to get one of those sockets if I end up upgrading injectors... Waiting on word back if custom nozzles can be created for a fraction of new injectors...
 

02DslPwr

Veteran Member
Joined
Dec 20, 2004
Location
Leander Texas
TDI
2002 Jetta Wagon, TDI
I love 130; I take it to the airport a few times a month. Actually 183A and IH-45 are 75mph now too. Only in Texas can you set your cruise at 90mph and not really be breaking the speed limit. :) (assuming your speedo if off by 3-5mph at that speed)

One mile from my house (@183A South) I can set my cruise at 80mph, then 15 miles later it goes up to 90mph. Highway ends a mile from the airport. Of course, its >$20 in tolls round-trip. Good things tolls are expensable.... :)
 

Tortus

Active member
Joined
Mar 13, 2012
Location
Leander, Texas
TDI
2010 Golf 2dr
I love 130; I take it to the airport a few times a month. Actually 183A and IH-45 are 75mph now too. Only in Texas can you set your cruise at 90mph and not really be breaking the speed limit. :) (assuming your speedo if off by 3-5mph at that speed)

One mile from my house (@183A South) I can set my cruise at 80mph, then 15 miles later it goes up to 90mph. Highway ends a mile from the airport. Of course, its >$20 in tolls round-trip. Good things tolls are expensable.... :)
Looks like you and I live VERY close to one another. I'm in Blockhouse Creek.

Toll roads are nice, but expensive as hell. The tolls cost a lot more than the fuel.

I'm looking to upgrade my turbo once all the kinks are worked out. If you decide to do the same you should drop me a note so I can check it out, or vice versa.
 

02DslPwr

Veteran Member
Joined
Dec 20, 2004
Location
Leander Texas
TDI
2002 Jetta Wagon, TDI
Looks like you and I live VERY close to one another. I'm in Blockhouse Creek.

Toll roads are nice, but expensive as hell. The tolls cost a lot more than the fuel.

I'm looking to upgrade my turbo once all the kinks are worked out. If you decide to do the same you should drop me a note so I can check it out, or vice versa.
I spent $1000 last year on tolls....:(:eek:

I'm on South St, aka Leander Dr/2243. I'm hoping my VNT17 will last another year or so. My end goal is 225hp at the wheels. Not sure if the 1765vk will do that. By the looks of another recent thread, I suppose not. Too bad the 2056 seems to have disappeared. There's another TDI guy here in Leander with Ryan's 2260 kit. We should all do lunch some day. A little Jardin never killed anyone! :)
 

A5INKY

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Joined
Sep 4, 2007
Location
Louisville, KY
TDI
2006 Jetta TDI, 2002 Eurovan Westphalia VR6
...My end goal is 225hp at the wheels. Not sure if the 1765vk will do that. By the looks of another recent thread, I suppose not...
I seriously doubt the 1756 is capable w/o excess smoke or drugs. I last dynoed at 203 whp with my 2056. Pretty clean tune mind you but I doubt there is more than another 10-15 HP there even if tuned to be a bit smokier.

If you really want 225 at the wheels go 2260 and be done with it. It is really not that laggy IMO.
 

storx

Veteran Member
Joined
Jan 16, 2006
Location
Earth!!
TDI
2009 Jetta CR140, 2010 Corvette Z06
The 2260 Turbo will support 260HP, other mods (cam, heads, injectors) may be needed.
If my memory recalls me, ryan forcasted that on the commonrail engines that no more then 240 can be made on the engine without head upgrades.. So something to think about. I beleive the 2260 is very capable of 270+ easy...
 

ryanp

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Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
I think 260BHP should be doable before EGT's get high due to a restrictive head design.
 

1972SS454

Veteran Member
Joined
Aug 27, 2010
Location
Fernandina Beach, FL
TDI
2009 Jetta TDI, 99.5 Jetta TDI
As much as I tried, I could not get the EGR cooler out with the subframe still in, so turn to the steering rack replacement section of the Bently's manual
When i deleted my EGR cooler I removed the LP EGR valve from the cooler (3 torx bolts), one of the coolant elbows and the EGR pipe that runs to the suction of turbo. This allowed me to remove the cooler without dropping the sub-frame. Hope this helps some others that are removing it.
 

greengeeker

Vendor
Joined
Feb 8, 2006
Location
Cambridge, MN
TDI
2002 Jetta GLS
I think 260BHP should be doable before EGT's get high due to a restrictive head design.
Aren't some of our crazies looking at the CR170 head? I know tdisyncro had his CR140 head ported to match the CR170 port size along with some huge valves.
 

brum

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Joined
Nov 30, 2009
Location
Bulgaria
TDI
Passat B5, 1.9 TDI, AFN
I seriously doubt the 1756 is capable w/o excess smoke or drugs. I last dynoed at 203 whp with my 2056. Pretty clean tune mind you but I doubt there is more than another 10-15 HP there even if tuned to be a bit smokier.

If you really want 225 at the wheels go 2260 and be done with it. It is really not that laggy IMO.
GTB1756VK compressor have bigger inducer compared to the GTB2056VK compressor inducer. Doesn't this mean that the compressor can flow more?

I've always wandered why the GTB2056VK can support more power than the GTB1756VK. The only bigger think in the GTB2056VK seems the be the exhaust side...
 

A5INKY

Vendor , w/Business number
Joined
Sep 4, 2007
Location
Louisville, KY
TDI
2006 Jetta TDI, 2002 Eurovan Westphalia VR6
GTB1756VK compressor have bigger inducer compared to the GTB2056VK compressor inducer. Doesn't this mean that the compressor can flow more?

I've always wandered why the GTB2056VK can support more power than the GTB1756VK. The only bigger think in the GTB2056VK seems the be the exhaust side...
GTB1756VK and GTB2056VK have identical compressor according to the database here:

http://forums.tdiclub.com/showpost.php?p=3186570&postcount=1
 

storx

Veteran Member
Joined
Jan 16, 2006
Location
Earth!!
TDI
2009 Jetta CR140, 2010 Corvette Z06
Aren't some of our crazies looking at the CR170 head? I know tdisyncro had his CR140 head ported to match the CR170 port size along with some huge valves.
If I could find an cr170 head I would swap it
 
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