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Thread: 2.5TDi V6 quattro Sport 180hp Turbochip

  1. #721
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    New map and i have more smoke but also a lot more power across the range, flywheel is barely taking it and it won't be long before it will throw in the towel ! Turbo is doing 2.6 Bars of boost, should be easily push enough air for my power target...
    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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  3. #722
    All-rod's Avatar
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    Did you manage to get that thing on dyno yet?

  4. #723
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    Went 2 days ago to AMD but got there at 5.30pm due to traffic and it was too late, they could not be bothered to put it on the rollers...maybe taking it there tomorrow, really is world apart to what it used to be...Hope to have some numbers to back the claims soon...
    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

  5. #724
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    Today got some time in the morning and took it to AMD in Thurrock for a dyno run. Results are just as predicted, 303 CV at 4200 rpm's, 299 Bhp and 530 Nm of torque. This is a pretty much smoke free map with linear power across the range and some fueling pulled to keep it clean and give the dual mass flywheel a chance ! Operator were so surprised that they did not even strapped it properly, they thought is a run of the mill a6 tdi with "just" 180Bhp ! They also did not turn on the fans which explain the heat soak in the intercooler so the subsequent readings were lower ! Chap took it for a spin and it was very, very impressed- complained about the clutch- he called it "juddery" !
    fjtwelve, PAULF, All-rod and 1 others like 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

  6. #725
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    Good stuff Chris. Glad you got to the 300 mark. Just out of interest, did you write the map yourself?

  7. #726
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    Quote Originally Posted by wesmaster View Post
    Good stuff Chris. Glad you got to the 300 mark. Just out of interest, did you write the map yourself?
    Base map yes, tweaking was done by a very smart chap in germany ! There was a lot of re-calibrating MAP sensors, boost values and deleting many boost limiters + pulling loads of fuel due to the Bosio Race nozzles pushing so much fuel trough ! Here's a little video i have made, AMD staff doesn't like people on their workshop's floor so had to keep away ! Click on the images for video...


    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

  8. #727
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    Well done Chris!
    Keep it up mate bedown to see you soon
    genuine parts =genuine service
    Treat it right it'll keep you on the road .

  9. #728
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    Class results.

    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 -

  10. #729
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    Basically same power as a BMW 535 d. Except you have a manual box instead of the slush box. Oh and quattro to make it stick instead of the squirrelly rear end. As you say maybe the only thing missing is bigger brakes, not that they are small now. If you started selling these as a conversion you'd have a queue pretty soon. Well done Chris, i'm delighted, you achieved everything i wanted to and then some. Not bad for a 13 year old barge with pushing 250k miles on it...
    2001 A6 Avant 2.5TDi quattro Sport 180hp+TurboDynamics MD438 hybrid+Bosio Race683s+3" exhaust+Celtic Tuning remap - now with adamss24 replaced with runabout
    2007 BMW 535d AM Sport + Celtic remap
    2004 A4 Avant 1.9TDi quattro Sport 130hp + Superchip - sold & replaced by
    2005 Audi TT 1.8T
    1988 Yamaha FJ1200 120hp finally traded after 23 years for
    1986 Yamaha FJ100 (1300 barrels shhh!) with too many bits to mention
    2011 BMW 320d M Sport son #1
    2004 Suzuki SV650 S son #2

  11. #730
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    Quote Originally Posted by fjtwelve View Post
    Basically same power as a BMW 535 d. Except you have a manual box instead of the slush box. Oh and quattro to make it stick instead of the squirrelly rear end. As you say maybe the only thing missing is bigger brakes, not that they are small now. If you started selling these as a conversion you'd have a queue pretty soon. Well done Chris, i'm delighted, you achieved everything i wanted to and then some. Not bad for a 13 year old barge with pushing 250k miles on it...
    Thank you very much for the kind words Martin, to be honest there's more in the old girl than this, map is very conservative and as i said loads of fuel pulled off from the low and mid range, to be honest it's such a nice drive i prefer driving this more than the s4 ! Thing is the car is heavy, i am running the turbo at a conservative 2.5 Bar of boost- this turbo can do 3 Bar easily ! Building a souped up engine for my old a4 avant and i hope to push over 350 Bhp with a GTB2260 hybrid with a 71mm compressor wheel... I will use a billet aluminium or even titanium wheel for improved spool...
    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

  12. #731
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    Well done and a good result so far - nice to see it on the rollers and all seemed to be good, must be great to drive compared to my standard 180 - wish I lived a bit nearer

  13. #732
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    Quote Originally Posted by Inskip75 View Post
    Well done and a good result so far - nice to see it on the rollers and all seemed to be good, must be great to drive compared to my standard 180 - wish I lived a bit nearer
    Thanks, it's a nice drive as it is, most cars with about 100Kw per litre will feel pretty nice to drive on a run ! I am doing a b6 estate for a chap in Ireland, so far new turbo, clutch & flywheel + larger injectors and a 3 Bar MAP sensor does make a big difference to the way it drives, sadly the propshaft bearing is not happy and it rumbles in 3rd and 4th with hard throttle...
    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. #733
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    Quote Originally Posted by adamss24 View Post
    Thank you very much for the kind words Martin, to be honest there's more in the old girl than this, map is very conservative and as i said loads of fuel pulled off from the low and mid range, to be honest it's such a nice drive i prefer driving this more than the s4 ! Thing is the car is heavy, i am running the turbo at a conservative 2.5 Bar of boost- this turbo can do 3 Bar easily ! Building a souped up engine for my old a4 avant and i hope to push over 350 Bhp with a GTB2260 hybrid with a 71mm compressor wheel... I will use a billet aluminium or even titanium wheel for improved spool...
    Fair play Chris, you are an absolute nutter! Keep up the good work! I'll pop in and see you when I'm next local to you.

  15. #734
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    Quote Originally Posted by wesmaster View Post
    Fair play Chris, you are an absolute nutter! Keep up the good work! I'll pop in and see you when I'm next local to you.
    No problem Wes, let me know when you're around, i will take you for a spin in it...there's still plenty left in it but need to go for a few more custom parts... The a6 is fine as a daily driver but it's by no means "sporty" ! I think a similar powered engine in a 1400Kg avant will be much more lively and what i like on the b5 platform is lack of traction aids which spoil all the fun !
    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

  16. #735
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    Do you have a graph of the map (one that you can post up)? interested to see what the torque curve looks like
    If it's not longitudinal and it's not Quattro..it's not an Audi
    VCDS (VAG-COM) HEX-CAN USB cable carrying member
    2005 A4 DTM 2.0 TFSi Quattro :364Bhp/477NM - Mapped by MRC Tuning
    Hybrid K04 Project ongoing (link to Build thread)

    DMFW + Clutch For Sale



  17. #736
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    Quote Originally Posted by solaris View Post
    Do you have a graph of the map (one that you can post up)? interested to see what the torque curve looks like
    Here you go, looks like i hit bandwidth limit again on photobucket...
    Attached Images Attached Images
    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

  18. #737
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    Not much to report apart from having to adjust a little the stop screw and actuator due to filling with some contaminated fuel at a BP petrol station down in Swindon ! I only put £20 worth of regular fuel, the old girl seems to like the Shell fuel save much more !
    Took the filter off after having sort of limp mode and found oily/watery mixture in the fuel filter, topped up with Shell's regular and taking it easy ! Next i am looking at fitting a larger, more efficient FMIC, however i don't like chavy intercoolers that add more lag but look cool ! I like function over form me...
    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

  19. #738
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    Hello adamss24,
    I would like to know if the dyno graph values are measured at the quattro wheels or are recalculated at the crankshaft of the engine?

    Thank you in advance.
    Best regards.

  20. #739
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    Quote Originally Posted by _Technics View Post
    Hello adamss24,
    I would like to know if the dyno graph values are measured at the quattro wheels or are recalculated at the crankshaft of the engine?

    Thank you in advance.
    Best regards.
    Most uk dyno's read power at the crank, it's only in the states people use wheel horse power...

    Bought a 60mm titanium compressor wheel to fit on a gtb2260vk turbo, this will take any boost levels as it's much, much stronger than aluminium wheels...10 full blades so it will push silly boost on high speed too !

    I will have a few hybrid turbos available next week, some are brand new, some are used in very good condition with few thousand miles on them... They will do 250-300 Bhp, depending on spec. Please pm if interested...
    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

  21. #740
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    Sadly today the old girl been involved in a hard shunt, some idiot lorry driver on his mobile did get into the side of me writing the car off more likely ! The pillar took the hit, rear door won't open and the front door won't close anymore- it did opened fine from inside ! I was travelling at 30 Mph and he just did pulled on me- did not even have time to break or anything ! Anyway, i will be breaking the car for parts, the engine will get to live into another project so it's not all wasted !
    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

  22. #741
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    What a bummer! after all you hard work.

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    Sorry to hear about the car Chris, fairly gutting after you put all the work into a car. At least you are OK which is the main thing, steel can be mended or replaced, bones and skin are a little more difficult .

    Do you not thinK that the standard turbine side of a 2260 is a little small for 350bhp and would be a restriction. It's ok putting ever bigger compressor wheels wheels on but getting high manifold pressures will give you high EGT and reduced flow potentially.
    Have you ever tried connecting a gauge to measure manifold pressure ?.

    Karl.
    Karls 312bhp A4 3.0 TDI build thread http://www.audi-sport.net/vb/audi-s4...ld-thread.html

  24. #743
    All-rod's Avatar
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    Really sad day man, sorry to see this happened.
    Was looking forward to see it pass 400...
    Stock 02 Allroad, AKE, Tip Auto.

  25. #744
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    Some pictures of the carnage !
    Attached Images Attached Images
    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

  26. #745
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    Few more...
    Attached Images Attached Images
    Last edited by adamss24; 20th March 2014 at 23:01.
    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

  27. #746
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    Quote Originally Posted by desertstorm View Post
    Sorry to hear about the car Chris, fairly gutting after you put all the work into a car. At least you are OK which is the main thing, steel can be mended or replaced, bones and skin are a little more difficult .

    Do you not thinK that the standard turbine side of a 2260 is a little small for 350bhp and would be a restriction. It's ok putting ever bigger compressor wheels wheels on but getting high manifold pressures will give you high EGT and reduced flow potentially.
    Have you ever tried connecting a gauge to measure manifold pressure ?.

    Karl.
    Karl, the turbine i was thinking to use is from the gt23/25 series, it's rather big compared with the stock gtb2260vk jobbie ! Darkside is stating 350 Bhp for their GTB2566vk on their website and this is a rather conservative estimate- they can run 35psi all day long !

    I ran 303 Bhp with 2.6 Bar of boost on a very, very conservative tune- pretty much smoke free ! I don't have a EGT gauge but i can hear the engine when there's too much EMP as the exhaust valves tend to stay open and the engine sounds rattly and coarse...

    I have just took delivery (today/sod's law !) of a custom made titanium billet compressor wheel for the gtb2260vk, it's a 10 blades wheel which will take ANY boost ! The wheel is heavier than a similar billet aluminium compressor wheel but it's much, much stronger !
    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

  28. #747
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    Hope your ok Chris ?(thats no consolation though)
    Think of it as fate and the possibilities of a bigger and more crazy build .
    genuine parts =genuine service
    Treat it right it'll keep you on the road .

  29. #748
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    Quote Originally Posted by gtiboy View Post
    Hope your ok Chris ?(thats no consolation though)
    Think of it as fate and the possibilities of a bigger and more crazy build .
    Not sure mate, you put a lot money into the car which is Queen's property in the end !?! I actually don't feel sorry, a car it's just a car- I am fine and that's what matters ! Might be going for a b5 rs4 soon and still tweak my allroad !

    I might be putting the engine into my lighter b5 shell, however the ECU on that needs chipping and it's a bit more involved when tuning compared with ECU you can flash trough Obd port.
    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

  30. #749
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    Very sorry to read this on hols in tenerife - but at least no injury to you - sort of end of an era

  31. #750
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    Gutted
    2001 A6 Avant 2.5TDi quattro Sport 180hp+TurboDynamics MD438 hybrid+Bosio Race683s+3" exhaust+Celtic Tuning remap - now with adamss24 replaced with runabout
    2007 BMW 535d AM Sport + Celtic remap
    2004 A4 Avant 1.9TDi quattro Sport 130hp + Superchip - sold & replaced by
    2005 Audi TT 1.8T
    1988 Yamaha FJ1200 120hp finally traded after 23 years for
    1986 Yamaha FJ100 (1300 barrels shhh!) with too many bits to mention
    2011 BMW 320d M Sport son #1
    2004 Suzuki SV650 S son #2

  32. #751
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    Quote Originally Posted by fjtwelve View Post
    Gutted
    It's not everything wasted Martin, the engine will be swapped in my old a4 quattro- which has been neglected since buying the a6 from you ! It's sad to break a good car especially when it was running it's best ! Not to worry though, just getting a gtb2260 ready to be fitted with a 60mm titanium compressor wheel then the gearbox from the a6 will get fitted to the allroad and the engine/clutch/flywheel will be fitted to the a4...might keep that as a track car and strip all the un-necessary junk of it for even more weight saving ! I have too many parts to build a good car which will show a clean pair of heels to most called "sports" cars on the road ! Here's a few teasers:




    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

  33. #752
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    Hi Chris

    Just been catching up on this thread. Talk about a roller coaster ride, just as you seem to be getting the power you wanted some duffus of a lorry driver stopped you continuing !! bugger
    Like you said though onwards & upwards and move onto the next project. Good luck with that and keep us all posted with a new thread.
    Have you done any work on the modern V6s yet? should be looking at remap and exhaust soon before going down turbo route poss from Darkside.

    All the best fella and must catch up soon.
    1998 A6 Avant 2.5TDI Retired at 185k miles
    2006 A6 Avant 3.0TDI S Line Quattro

  34. #753
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    Doing a v6 tdi d3 a8 now, the engine ran away due to faulty injectors which leaked so badly the fuel ran into the sump till the seals blown. In your case George, the turbo fitted is a Bv50 which is not directly compatible with the gtb2260vk darkside sells ! You can rebuild the bv50 with some billet compressor wheels so it's not all wasted ! Exhaust, map and hybrid turbo will unleash a lot of torque and Bhp in your a6.
    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

  35. #754
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    Hi chris been enjoying reading your thread and good to see someone so active on the forum who is knowledgeable and happy to give out advice. I just wondered if there would be any gain to be had fitting a pair of 2.7t inter coolers to a diesel? They LOOK as if they will have a better flow rate and maybe there would be gains from this. They're almost direct fit only the pipe work would need modifying and as I'm a TIG welder that's no problem for me.
    The A4 looks nice as it is and should be a real handful once done!
    Keep up the good work, glad all your hard work on the engine wasn't destroyed by that idiot driver
    Allroad 2.5TDI 04 Manual on 19x9.5 BBS LM 402'd 30mm
    Uprated air suspension system, working on second air tank in spare wheel well.
    A8 4.2QS 98 on 20x10" sold

  36. #755
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    Quote Originally Posted by CHRISTOPHÉ View Post
    Hi chris been enjoying reading your thread and good to see someone so active on the forum who is knowledgeable and happy to give out advice. I just wondered if there would be any gain to be had fitting a pair of 2.7t inter coolers to a diesel? They LOOK as if they will have a better flow rate and maybe there would be gains from this. They're almost direct fit only the pipe work would need modifying and as I'm a TIG welder that's no problem for me.
    The A4 looks nice as it is and should be a real handful once done!
    Keep up the good work, glad all your hard work on the engine wasn't destroyed by that idiot driver
    Thanks Chris, to be honest if the intercoolers cores are bigger then they might be more efficient, however diesels have pretty efficient intercoolers out of the box, i would only use all metal coolers as they will sustain high levels of boost without splitting !

    Thanks for the good wishes, yes the a4 will be a handfull when done, i have the option to fit a gtb2260vk on it or a gt2559v as well, i have allready all ingredients but not enough time to fit the chipped ecu and play with it ! Sadly the car does not look as good as in the pictures, it's got a few dents after spending the last 2 years in a car park however it does scrub up nicely ! I will just look at getting a few months of use out of it, maybe looking at using it as a track car as the chassis is sorted already or break it altogether and use the parts on a kit car !
    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

  37. #756
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    Nice thread, looking to up the anti on my 2.5tdi Allroad once the ebay camshaft kit is fitted. Plan is to clean all the intake manifolds and crossover, blank the egr and oil breather (install a catch can) and install wmi

    Then look to see what can be done on the exhaust and remap side of things

  38. #757
    All-rod's Avatar
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    Quote Originally Posted by TDIAllroad View Post
    Nice thread, looking to up the anti on my 2.5tdi Allroad once the ebay camshaft kit is fitted.
    Which kit did you buy, have a link?
    Stock 02 Allroad, AKE, Tip Auto.

  39. #758
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    Quote Originally Posted by All-rod View Post
    Which kit did you buy, have a link?
    PREMIUM 2.5 TDI V6 VALVETRAIN, V-BELTS & TIMING REPAIR KIT AUDI A4 A6 A8 PASSAT | eBay

    its the most loved kit on the forum i believe
    All-rod likes this.

 

 

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