Single Turbo option for 400hp 1.9 PD

Denali376

Active member
Joined
Feb 4, 2020
Location
Lucedale,Mississippi
TDI
06 Jetta tdi BRM 5 Speed, 06 vw Jetta tdi brm DSG
As the title implies, I’m asking for advice/turbocharger options for a street able 400hp 1.9 PD/MK5/DSG gearbox

I’ve assembled (USA) the Engine (Longblock/fuel/cooling ect.) to accommodate increased output. Required machining was performed by Engine Machine Shop @ Mobile, Al.

X4 160% Wuzetem nozzles, calibrated on BB. OE fuel filter housing w/ modified distribution/ elimination of fuel recirculation valve. 3/8 Gates pushlok feed/return hose throughout.

maXpeeding H-beam connecting rods, 3/8 ARP 2000 hardware/ small end bushings replaced with Glyco pin bushings.(Glyco bushings are not only slightly thicker but use a rifled design for improved lubrication)

Kolbenschmidt STD pistons/ 43mm bowls/ DFL skirts/ ceramic tops/ funneled oil cooling inlet/ Goetze piston rings w/ LKZ-Diamondblayered running face + phosphated. The second “compression” rings are “Gapless” Modified @ Total Seal.

CJAA crankshaft anchored using ARP main cap hardware

Cylinder head has been heavily ported. Std inlet & exhaust valves.

Dbilas 272 camshaft

3” downpipe/exhaust
Aftermarket S3 intercooler 2.5” inlet/outlet
2.5” intercooler piping
 

adamss24

Veteran Member
Joined
Nov 2, 2005
Location
Great Britain
TDI
audi a4 2.5 tdi 98 quatrro 6speed
Now you can get a hybrid based f10 Bmw fitted with some really large compressor: 69 or even 73mm, turbine AMG 3.0 tdi style or from gt2559v from Renault mascot/Saab 3.0 tdi or Renault veil satis 3.0 dci… the gt2559v turbine has only one sealing ring on shaft and they might let oil pass the seal into exhaust, the AMG style turbine has twin seal design.
Alternately you can get a s300v turbo and convert the vgt mechanism to electronic actuator…it’s a large turbo and you might have to remote mount it…surge is the main problem !
 

TDIMeister

Phd of TDIClub Enthusiast, Moderator at Large
Joined
May 1, 1999
Location
Canada
TDI
TDI


 
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adamss24

Veteran Member
Joined
Nov 2, 2005
Location
Great Britain
TDI
audi a4 2.5 tdi 98 quatrro 6speed
There are many that claims they can build hybrid gtb turboss to do 400 bhp, in reality many cannot muster more than 350 bhp...the f10 turbo is the largest medium frame turbo that comes standard on passenger cars, it has a better flowing hotside compared to mercedes or audi hotside and has billet compresor wheel GTX style from factory ! Bloody large inducer too...
 

Denali376

Active member
Joined
Feb 4, 2020
Location
Lucedale,Mississippi
TDI
06 Jetta tdi BRM 5 Speed, 06 vw Jetta tdi brm DSG
Now you can get a hybrid based f10 Bmw fitted with some really large compressor: 69 or even 73mm, turbine AMG 3.0 tdi style or from gt2559v from Renault mascot/Saab 3.0 tdi or Renault veil satis 3.0 dci… the gt2559v turbine has only one sealing ring on shaft and they might let oil pass the seal into exhaust, the AMG style turbine has twin seal design.
Alternately you can get a s300v turbo and convert the vgt mechanism to electronic actuator…it’s a large turbo and you might have to remote mount it…surge is the main problem !
I’ve seen some nice stuff on Pioneering Performance website
 

Denali376

Active member
Joined
Feb 4, 2020
Location
Lucedale,Mississippi
TDI
06 Jetta tdi BRM 5 Speed, 06 vw Jetta tdi brm DSG


I would have already purchased turbosystems big GTD if it’s wasn’t $2000
 

tdi_my live

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Joined
Jul 24, 2011
Location
Germany
TDI
Skoda Fabia
At what point you want 400hp? At 4000rpm, at 4500rpm or at 5000rpm?
At 4000rpm you need round 144mg injection, at 4500rpm round 133mg and at 5000rpm round 125mg
The Motor need air at 4000rpm 2400mg, at 4500rpm 2200mg and at 5000rpm 2100mg, all with a little bit smoke.
If the turbo can deliver this air, the pressure have to be at 4000rpm 4370hpa, at 4500rpm 4000hpa and at 5000rpm 3800hpa.
 

Denali376

Active member
Joined
Feb 4, 2020
Location
Lucedale,Mississippi
TDI
06 Jetta tdi BRM 5 Speed, 06 vw Jetta tdi brm DSG
At what point you want 400hp? At 4000rpm, at 4500rpm or at 5000rpm?
At 4000rpm you need round 144mg injection, at 4500rpm round 133mg and at 5000rpm round 125mg
The Motor need air at 4000rpm 2400mg, at 4500rpm 2200mg and at 5000rpm 2100mg, all with a little bit smoke.
If the turbo can deliver this air, the pressure have to be at 4000rpm 4370hpa, at 4500rpm 4000hpa and at 5000rpm 3800hpa.
i know this is nearly 2 years old but do you map?
 

Denali376

Active member
Joined
Feb 4, 2020
Location
Lucedale,Mississippi
TDI
06 Jetta tdi BRM 5 Speed, 06 vw Jetta tdi brm DSG
I have one nearly new GTD2263VZK available if you want. 1000eur + shipping.
I appreciate you for offering although too small amigo, I’ve blown a GTD22 already and have a GTB2265VKLR atm which has been great, definitely limiting factor for the setup atm.
 

ssullivan

Veteran Member
Joined
Aug 23, 2021
Location
NV
TDI
2001 Jetta
You're in big turbo land! HE341, HE351, or HX35 (has to have 12 cm2 housing or less, it is stamped in exh housing) fit your budget and would be close to 400 whp. You plan on revving your engine right?

He says in the comments it hits full boost at 3500 rpm in 3rd gear with 12cm2 divided. I would love to try a divided 12cm housing on a proper twin scroll manifold.

 
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ssullivan

Veteran Member
Joined
Aug 23, 2021
Location
NV
TDI
2001 Jetta
To clarify, if you do not have a true twin scroll manifold, get the 8 cm2 HE351W/HX35.
 

adamss24

Veteran Member
Joined
Nov 2, 2005
Location
Great Britain
TDI
audi a4 2.5 tdi 98 quatrro 6speed
I would really use an s200v with the 50/72 mm billet titanium compresor wheel…as I said, surge is your only enemy, that turbo will make 3 bar of boost at 3500 rpms.
You can also us s200v with the 46/72 mm compressor wheel, I would swap to billet EFR wheel or the new generațion billet wheels from BW catalogue !
 

ssullivan

Veteran Member
Joined
Aug 23, 2021
Location
NV
TDI
2001 Jetta
OP already said $2k is out of the budget unfortunately, hence Holset (which are great turbos). From Borg-Warner looks like the S251 with .48 a/r would be an option, $850. Personally, I would go genuine new or used Holset and save the quid.

Nice thing about a non-hybrid WG turbo is it is hard to get surge since the turbine and compressor are well-matched.
 
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