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Thread: 2.5 AKE engine to 250Bhp?

  1. #1
    AlexGSi2000's Avatar
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    2.5 AKE engine to 250Bhp?

    I know this must have been asked a million times before, but im looking to squeeze abit more power from my 2.5TDi.

    I think the engine is pretty strong - having a top end rebuild (cams.etc) 15,000 miles ago.

    So far I have had the ECU remapped and had a full stainless exhaust fitted with both cats removed.

    I believe the power output to be around 219bhp at the fly - looking to achieve 240/250bhp within a budget.
    I want to avoid custom parts / fabrication if possible and try and fit same size / dimension components.

    So far, I am thinking of going down the line of injector nozzles (Bosio?) not sure on the ones I will need,
    also "hybrid" turbo - VNT20 with a different compressor wheel.etc so it bolts on to the existing manifold.etc
    Im hoping the two things above, along with a custom re-map will see me to the figure I am hoping for, do you think this would be possible?

    Thanks.

    2002 A4 Avant Quattro Sport 2.5 V6 TDi - 219Bhp - Votex
    BCS Automotive Turbo-Back - Remap -
    19" RS6 Reps - B6 S4 Brakes - Symphony II+
    - Weitec GT
    - 2001 Honda CBR600-FS1 -

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  3. #2
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    Subscribing.

    all the threads I have found appear old. adamss24 seems to know his stuff from my reading.

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    Grab a bear and read away!

    2.5TDi V6 quattro Sport 180hp Turbochip

    EDIT - I left that because it's funny, I obviously meant a beer!
    Ingolstance Read about my A6 HERE.

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    Quote Originally Posted by quattrojames View Post
    Grab a bear and read away!

    2.5TDi V6 quattro Sport 180hp Turbochip

    EDIT - I left that because it's funny, I obviously meant a beer!
    i read that start to finish earlier. Are there any other threads?

    thanks

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    250 Bhp is easy, all you need nozzles, hybrid turbo and a good tune ! Bosio pp683 will be well suited to your power goal, however i would go to race 683 but they are getting hard to get hold of. I might have a hybrid turbo for sale in the new year, it's freshly rebuilt with new internals based on a gt2260v- plug and play on any v6 tdi engine. Race 683 nozzles and this turbo made my 2 tonnes allroad feel like a supercar and gave me wiplash ! I might also have a full turbo kit based on a GTB2260vk also plug and play ! I am going for a hybrid GTB2566vk for the old a6, maybe that will clear the smoke from the race nozzles !









    FOR SALE:
    -Golf mk 5/audi a3 1.6 FSI fuel pump, brand new genuine part boxed + seals
    -audi a3 (1998 to 2003) genuine clutch slave cylinder to fit 1.6 engines BRAND NEW
    -Rear bush press tool to fit new rear axle bushes on Golf Mk3/4, Audi a3/S3, Seat Leon/Toledo, Skoda Octavia mk 1/2 used once

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    AlexGSi2000's Avatar
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    Many thanks for the advice!
    I'm guessing the injectors will need balancing once they have the new nozzles fitted?

    2002 A4 Avant Quattro Sport 2.5 V6 TDi - 219Bhp - Votex
    BCS Automotive Turbo-Back - Remap -
    19" RS6 Reps - B6 S4 Brakes - Symphony II+
    - Weitec GT
    - 2001 Honda CBR600-FS1 -

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    diesel bobs your place
    2.5tdi Avant Q S 180 - 19" RS6 reps - chrome mirrors - ambient light package - cruise and dis retrofit - chrome side repeaters - front sline lowr conversion with cupra r splitter - rear lower valance with twin cut outs and exhaust tips - rs4 rear antiroll bar - puddle and footwell lights - sline door blades - fully colour coded - b8 autodimming mirror on custom window adapter - geuine aero wiper upgrade - genuine heated mirror upgrade

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    Yes, the new nozzles will need pop testing and balancing. I used dieselbob to balance the both sets of nozzles i got with the car from Martin/FJ Twelve but i left the race 683 nozzles fitted to the AKE injectors and the pp683 i've fitted to older AFB injectors.

    The Bosio 683 nozzles are designed to fit the older style injector body and for some reason the pilot injection cannot be adjusted too far on the AKE injectors.

    They will work in both injector bodies but it's easier to get higher pop pressures in the older style injectors and i still get slight idle shudder from the a6 and none from the allroad.

    Mind you the a6 is too quiet, the allroad engine has a little bark to it !
    BRILLO likes this.
    FOR SALE:
    -Golf mk 5/audi a3 1.6 FSI fuel pump, brand new genuine part boxed + seals
    -audi a3 (1998 to 2003) genuine clutch slave cylinder to fit 1.6 engines BRAND NEW
    -Rear bush press tool to fit new rear axle bushes on Golf Mk3/4, Audi a3/S3, Seat Leon/Toledo, Skoda Octavia mk 1/2 used once

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    AlexGSi2000's Avatar
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    I get abit of idle shudder too, but im guessing its down to one of the engine mounts on mine (the shock absorbed one)

    I have found a place fairly local to myself "united diesel" - will see if they can do them for me, I will get in touch with dieselbob also.

    2002 A4 Avant Quattro Sport 2.5 V6 TDi - 219Bhp - Votex
    BCS Automotive Turbo-Back - Remap -
    19" RS6 Reps - B6 S4 Brakes - Symphony II+
    - Weitec GT
    - 2001 Honda CBR600-FS1 -

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    I know Ryan at Darkside used to give loads of work to the chap at United Diesel but they stopped using him due to not satisfactory results. I know Darkside are using a diesel specialist based in Germany who is the best in Europe so far ! Would not hurt dropping Ryan's a pm for more details, i know they are still Bosio distributers in Uk so he might be able to hook you up with some nozzles.
    I would go with pp683 IF you don't intend going for more than 250-260 Bhp, if you need more power then going for the race 683 might be wise. Just expect some iddle shudder if the map is not right, i am still not happy with the map from Celtic Tuning but martin's a6 was a test mule a few years ago- maybe they've upped their game since then !?!
    FOR SALE:
    -Golf mk 5/audi a3 1.6 FSI fuel pump, brand new genuine part boxed + seals
    -audi a3 (1998 to 2003) genuine clutch slave cylinder to fit 1.6 engines BRAND NEW
    -Rear bush press tool to fit new rear axle bushes on Golf Mk3/4, Audi a3/S3, Seat Leon/Toledo, Skoda Octavia mk 1/2 used once

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    AlexGSi2000's Avatar
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    I think I may have sourced a set of PP683 injectors - the company are asking for a part number on my existing nozzle for some reason, starting DLSA - anyone know what this may be?

    2002 A4 Avant Quattro Sport 2.5 V6 TDi - 219Bhp - Votex
    BCS Automotive Turbo-Back - Remap -
    19" RS6 Reps - B6 S4 Brakes - Symphony II+
    - Weitec GT
    - 2001 Honda CBR600-FS1 -

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    Did you manage to get your pp683 nozzles Alex ? How much were they if you don't mind me asking ?
    FOR SALE:
    -Golf mk 5/audi a3 1.6 FSI fuel pump, brand new genuine part boxed + seals
    -audi a3 (1998 to 2003) genuine clutch slave cylinder to fit 1.6 engines BRAND NEW
    -Rear bush press tool to fit new rear axle bushes on Golf Mk3/4, Audi a3/S3, Seat Leon/Toledo, Skoda Octavia mk 1/2 used once

  14. #13
    AlexGSi2000's Avatar
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    Hi Chris,
    Managed to find some from a German website - worked out at around £580.
    I havent ordered them as of yet, as I saw the front suspension arms as being more important to replace - along with having a few other things iv needed to replace (alternator.etc)

    Still hoping to get a set this year!

    2002 A4 Avant Quattro Sport 2.5 V6 TDi - 219Bhp - Votex
    BCS Automotive Turbo-Back - Remap -
    19" RS6 Reps - B6 S4 Brakes - Symphony II+
    - Weitec GT
    - 2001 Honda CBR600-FS1 -

 

 

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