TDI CUA 240HP to 420HP attempt

Syncrogreg

Vendor
Joined
Feb 22, 2010
Location
Nashville TN
TDI
2.0 TDI CR SWAP ALWAYS FOR SALE
First TDI CUAA on US territory! Big power attempt 420HP ;-)

Having maxed out the other 150HP engine to 268BHP... I'm now moving to the 240HP engine code CUAA (the most powerful 2.0 TDI ever made in production) and hoping to make 420BHP out of that one...
Anyway here is the beast before install!
Huge intercooler!

700hp clutch!

An fittings everywhere!

An fittings everywhere!

150MG IQ injectors 2500Bar injection pressure system

Cp4.2 V2 high output pump!!!

I have 2x type Turbos to test G25-550 and gtb2566vk
Fixed turbo

Vgt

Talk soon!
Greg
 
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turbobrick240

Top Post Dawg
Joined
Nov 18, 2014
Location
maine
TDI
2011 vw golf tdi(gone to greener pastures), 2001 ford f250 powerstroke
Very cool to see someone here experimenting with the CUAA. Are you planning to run a single turbo?
 

Syncrogreg

Vendor
Joined
Feb 22, 2010
Location
Nashville TN
TDI
2.0 TDI CR SWAP ALWAYS FOR SALE
Yes the biturbo that came with it is great for 280-300 but extremely heavy setup and overcomplicated with a lot of chances to have something go wrong!

So I'll give a shot to the new g25-550 advertised to spool super early due to its new Aero.. fresh 2019 Garrett design . If it doesn't go well I'll put the good ol' trusted gtb2566vk the issue with these vgt turbos is the size of the shaft is ridiculously small and they don't like boost past 35 PSI but engine is rated for 45PSI from factory.
 

jhax

Veteran Member
Joined
Jan 24, 2012
Location
Golden, CO
TDI
96 Passat B4V, ALH engine out of a 2002 Jetta, some IE Rods and ASV Pistons. Nothing drivable yet though
Who are you? Does commissioner Gordon shine a special tdi light in the sky over Nashville and you come a callin'?
 

TheoSweden

Veteran Member
Joined
Jun 10, 2006
Location
Uppsala, Sweden
TDI
A3Q,A4Q, Passat Biturbo TDI
Nice project, following this!


I have a Passat with this engine remaped by DVX Performance in Belgium.


295hp 613Nm It drives just fantastic!!
 
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Yucca

Veteran Member
Joined
Apr 13, 2007
Location
Finland
TDI
ALH 388bhp, Polo 6R 2.0TDI CR GTC1752VZ
If G25-550 does not give enough throttle i might have VGT options for that power level and 45-50psi boost.
 

Yucca

Veteran Member
Joined
Apr 13, 2007
Location
Finland
TDI
ALH 388bhp, Polo 6R 2.0TDI CR GTC1752VZ
That kind of 2260 based hybrid is not best choice for any motor.

I was thinking Borg Warner B2 - series VNT -turbo. Compressor wheel size matched with power goal.
 

Syncrogreg

Vendor
Joined
Feb 22, 2010
Location
Nashville TN
TDI
2.0 TDI CR SWAP ALWAYS FOR SALE
Nice project, following this!
I have a Passat with this engine remaped by DVX Performance in Belgium.
296hp 614Nm It drives just fantastic!!
Cool what is the max RPM you put power? I was thinking about using power to 5000 rpm then start to lower fueling... Still usable power but defuel some from 5000 to 5100 RPM and defuel consireably at 5200 so I don't stress these stock internals...
 
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PETERHUK

Member
Joined
Sep 8, 2015
Location
Ukraine, Kyiv
TDI
GOLF MK 2, AFN SWAPPED
I thought that this engine fits only with dsg dq 500������
How did you manual gearbox swapped?
 
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Syncrogreg

Vendor
Joined
Feb 22, 2010
Location
Nashville TN
TDI
2.0 TDI CR SWAP ALWAYS FOR SALE
It's a tube chassis with Porsche Boxster front and rear components mid engine TDI using Boxster transaxle.


Quaife diff
Driveshaft shop CV axles 700HP
South bend clutch 700HP
Braid rims
Soft compound tires
Antigravity battery

VW bug composite carbon fiber/Kevlar/fiberglass body



Wet weight 1850LBS with driver


 
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Markus L

Veteran Member
Joined
Feb 12, 2015
Location
Finland
TDI
Caddy (14D) 1.9TDI 2-stage 400+bhp, Passat 3BG 4motion AVF
You need way bigger turbo to achieve 420bhp in Pikes Peak. You need to massively overspin G25-550 even at sea level to achieve that power at 5000 rpm.
 

Syncrogreg

Vendor
Joined
Feb 22, 2010
Location
Nashville TN
TDI
2.0 TDI CR SWAP ALWAYS FOR SALE
You need way bigger turbo to achieve 420bhp in Pikes Peak. You need to massively overspin G25-550 even at sea level to achieve that power at 5000 rpm.
I'll let you know how Dyno sesh goes! This head flows so much more than previous gens it's a different breed for sure!
 

Markus L

Veteran Member
Joined
Feb 12, 2015
Location
Finland
TDI
Caddy (14D) 1.9TDI 2-stage 400+bhp, Passat 3BG 4motion AVF
There's no use of head flow if turbo doesn't flow enough.
 

Yucca

Veteran Member
Joined
Apr 13, 2007
Location
Finland
TDI
ALH 388bhp, Polo 6R 2.0TDI CR GTC1752VZ
What abaut cams? Normally stock CR cams support 2000-3000rpm zone and flow is very poor after 4500rpm. Does that motor have better cams or is there upgrade cams available?

If we are talking sea levels, those turbos are quite ok with 2.5boost. Not so when you need 3bar or more.
 

Syncrogreg

Vendor
Joined
Feb 22, 2010
Location
Nashville TN
TDI
2.0 TDI CR SWAP ALWAYS FOR SALE
What abaut cams? Normally stock CR cams support 2000-3000rpm zone and flow is very poor after 4500rpm. Does that motor have better cams or is there upgrade cams available?
If we are talking sea levels, those turbos are quite ok with 2.5boost. Not so when you need 3bar or more.
Actually I'll be right around the most efficient spot on the map at 2.8 bars (40PSI) engine can handle 50 so I have a good safe zone. For the cams this CUAA has a different profile with more lift and allow more power to be made at higher RPM's
 

[486]

Top Post Dawg
Joined
Mar 1, 2014
Location
MN
TDI
02 golf ALH
man, all this neato stuff coming along
shame we probably won't get that nice base of an engine over here
 

Syncrogreg

Vendor
Joined
Feb 22, 2010
Location
Nashville TN
TDI
2.0 TDI CR SWAP ALWAYS FOR SALE
Thanks! That looks like a fantastic daily driver. Do you know what type of boost and max EGT on your stage1 tune?
 

TheoSweden

Veteran Member
Joined
Jun 10, 2006
Location
Uppsala, Sweden
TDI
A3Q,A4Q, Passat Biturbo TDI
No sorry in this case I dont know that. Just driving with a smile on my face.


Perfect daily and for towing the racecar. :)
 

turbobrick240

Top Post Dawg
Joined
Nov 18, 2014
Location
maine
TDI
2011 vw golf tdi(gone to greener pastures), 2001 ford f250 powerstroke
Good god, that tuned torque curve is incredible!
 

Markus L

Veteran Member
Joined
Feb 12, 2015
Location
Finland
TDI
Caddy (14D) 1.9TDI 2-stage 400+bhp, Passat 3BG 4motion AVF
Actually I'll be right around the most efficient spot on the map at 2.8 bars (40PSI) engine can handle 50 so I have a good safe zone. For the cams this CUAA has a different profile with more lift and allow more power to be made at higher RPM's
First you should read this
Then you should think about ambient air pressure at Pikes Peak. I was just doing some turbo speed measurements at 2000 m above sea level. Ambient pressure was 800 mbar.

You will realize that turbo is way over the sweet spot and max rpm.
 

sardo_67

Veteran Member
Joined
Feb 15, 2010
Location
CT
TDI
2003 Jetta
wow that's a crazy bug.


what is this motor stock in for the EU market?
 

Yucca

Veteran Member
Joined
Apr 13, 2007
Location
Finland
TDI
ALH 388bhp, Polo 6R 2.0TDI CR GTC1752VZ
Actually I'll be right around the most efficient spot on the map at 2.8 bars (40PSI) engine can handle 50 so I have a good safe zone. For the cams this CUAA has a different profile with more lift and allow more power to be made at higher RPM's
Good to hear that it uses better cams (and maybe better head also).

Sea level, 2.5bar (PR 3.5 compressor map), 45lbs, 75% efficiency, 180-185krpm, just edge of compressor map. 2.5bar is not enough for that power / flow.

First look that compressor map PR4 level (ideally 3bar boost at sea level)

Then think / calculate that situation when ambient pressure is 800mbar...
 
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Yucca

Veteran Member
Joined
Apr 13, 2007
Location
Finland
TDI
ALH 388bhp, Polo 6R 2.0TDI CR GTC1752VZ
My choice for that kind of goal would be compressor wheel from borg s252sx-e.

Compressor map: https://www.full-race.com/wp-content/uploads/2018/02/S252SX-E-Compressor-Map-800x664.png

I would be very nice for that kind of approx. 45lbs goal.

Lets think you would make 420bhp @ 45lbs when using 3bar boost pressure. 1bar atmos = sea level. In compressor map point would be PR4.0 (70% eff)

That same thing when boost 3bar and ambient air pressure in mountains is only 800mbar. Compressor map point would be PR4.75 (64% eff, overspeed 1-5%).
 
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