TDI CUA 240HP to 420HP attempt

[Syncrogreg]

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

 

[turbobrick240]

Very cool to see someone here experimenting with the CUAA. Are you planning to run a single turbo?

 

[Syncrogreg]

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]

Who are you? Does commissioner Gordon shine a special tdi light in the sky over Nashville and you come a callin'?

 

[TheoSweden]

Nice project, following this!


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


295hp 613Nm It drives just fantastic!!

 

[Yucca]

If G25-550 does not give enough throttle i might have VGT options for that power level and 45-50psi boost.

 

[Syncrogreg]

If G25-550 does not give enough throttle i might have VGT options for that power level and 45-50psi boost.

I think I'm fine I have both best choices on the table but I'm still curious what do you have in mind?

 

[Yucca]

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]

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...

 

[PETERHUK]

I thought that this engine fits only with dsg dq 500������
How did you manual gearbox swapped?

 

[1854sailor]

Sweet! In what cars is this a stock engine? Nothing on this side of the pond I'm assuming...

 

[CNGVW]

He runs a rally Beetle at Pikes peak

 

[Syncrogreg]

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

 

[adamss24]

That little bug looks well cool ! I like it a lot...

 

[Markus L]

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]

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]

There's no use of head flow if turbo doesn't flow enough.

 

[Yucca]

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]

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]]

man, all this neato stuff coming along
shame we probably won't get that nice base of an engine over here

 

[TheoSweden]

This is how power figures look stock vs very good tuned.

 

[Syncrogreg]

Thanks! That looks like a fantastic daily driver. Do you know what type of boost and max EGT on your stage1 tune?

 

[TheoSweden]

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]

Good god, that tuned torque curve is incredible!

 

[Markus L]

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]

wow that's a crazy bug.


what is this motor stock in for the EU market?

 

[TheoSweden]

wow that's a crazy bug.


what is this motor stock in for the EU market?

VW Passat 2015-

 

[Yucca]

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...

 

[Yucca]

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%).

 

[Syncrogreg]

600 mbar atmo at pikes peak

Greg