a6 allroad v6 diesel tuning

nick75

nick75

Registered User
Joined
Sep 14, 2015
Messages
20
Reaction score
2
Points
3
Using this car as a daily worker and want to do some work on it as a project. Looking for any suggestions to improve power/response. . Thinking about new cams perhaps unless anyone has other thoughts. Also looking at exhaust replacement and blanking egr thoughts?
I have fitted a new air pump for the suspension already but I have been looking a complete air kits to upgrade existing has any one done this work and are you happy with the results.
 
  • Like
Reactions: Diesel25C5
Is there a problem with the cams?, if not then no point in changing them. If you want to tune a diesel a remap is a good start. Most people are usually happy with this, If you want more then changing the turbo and upgrading the exhaust / intercooler is a good start along with another remap.
What engine is in the car ?
 
desertstorm said:
Is there a problem with the cams?, if not then no point in changing them. If you want to tune a diesel a remap is a good start. Most people are usually happy with this, If you want more then changing the turbo and upgrading the exhaust / intercooler is a good start along with another remap.
What engine is in the car ?
Click to expand...
The engine is 2.5 v6 diesel. 2003 year. Have read that the cams can ware but as far as I'm concerned the engine is currently running ok just single turbo lags. Still learning about the car and codes that tec save use
 
nick75 said:
The engine is 2.5 v6 diesel. 2003 year. Have read that the cams can ware but as far as I'm concerned the engine is currently running ok just single turbo lags. Still learning about the car and codes that tec save use
Click to expand...
I belive the car is b4 c5
 
The resident expert on these is Chris Adams @adamss24 . What he doesn't know about them isn't worth knowing.
 
I have tuned these engines to over 300 Bhp with great improvement in torque and Bhp. The clutch will hold 250-270 Bhp but will strugle with more than 500Nm of torque. I can put a nice tuning package for you, last one i have done for a forum member dyno'ed to 290 Bhp with just bolt on mods ! If you want to read more about my projects then search a6 turbochip and allroad ABT sportsline... My old allroad had much more potential than my a6 due to having a 3 plunger head which works wondera with the large nozzles !
 
adamss24 said:
I have tuned these engines to over 300 Bhp with great improvement in torque and Bhp. The clutch will hold 250-270 Bhp but will strugle with more than 500Nm of torque. I can put a nice tuning package for you, last one i have done for a forum member dyno'ed to 290 Bhp with just bolt on mods ! If you want to read more about my projects then search a6 turbochip and allroad ABT sportsline... My old allroad had much more potential than my a6 due to having a 3 plunger head which works wondera with the large nozzles !
Click to expand...
Sounds good. 250bhp would be a good target as I don't want to end up eating clutch or blowing the engine.. if it's available as straightforward swap spanner work all the better.
 
nick75 said:
Sounds good. 250bhp would be a good target as I don't want to end up eating clutch or blowing the engine.. if it's available as straightforward swap spanner work all the better.
Click to expand...
Don't worry much about blowing the engine, if in good health they are tough as old boots ! 250 Bhp is adeqvate on the allroad, it's a heavy lump of steel ! Give me a shout when you're ready and i will make you some alloy boost pipes and modify a turbo to fit your car. What do you want a plug and play solution ? I have a 2056 turbo with billet compressor wheel and uprated turbine all machined in original housing which will do your power target without much bother. It's also quicker on boost than the original turbo due to modern design of turbine and compressor wheel. I run this turbo on a 2004 audi allroad with a 3" free flowing exhaust and it's wicked- goes to 250km/ hour and the fuel economy improved by over 1L/100Km. The clutch holds fine but it was a new one i fitted last summer. I have done over 10k in the car and it's one of the most reliable allroads i had to date...
 
  • Like
Reactions: opronnie and xpoweruk
Turbo sounds good, what sort of money we talking ? Alloy boost pipes would solve my hunt for silicone replacement and work better to. Am thinking I may need to do a clutch change it runs fine but now on 180000 and never been done so I can see extra power finishing it off... is there a specific one you'd recommend? .
 
Hi, i have only used Sachs SRE clutches, they will handle anything you can throw at them and feel as close to OEM clutch as you can get !
 
  • Like
Reactions: nick75
Yep, 290 bhp with bolt-ons. Cams will be worn probably. (mine were worn (2002 model) enough to start throwing the rocker arms).
Torque will be a consideration. I had new Clutach and flywheel (Sachs) but now with over 500 nm, i get drive train "rumbles" if the revs are too low. You have to change your driving style a little. Chris currently uses the Garrett 2260 vk, which is a little laggy, but once you hit boost you think you are driving a S4....
 
two left feet said:
Yep, 290 bhp with bolt-ons. Cams will be worn probably. (mine were worn (2002 model) enough to start throwing the rocker arms).
Torque will be a consideration. I had new Clutach and flywheel (Sachs) but now with over 500 nm, i get drive train "rumbles" if the revs are too low. You have to change your driving style a little. Chris currently uses the Garrett 2260 vk, which is a little laggy, but once you hit boost you think you are driving a S4....
Click to expand...
I'm spending the winter researching options and working out prices. I have read that the cams wear and it's something I've been looking at. I have wondered weather to buy another one to use as the project car. I am considering the idea of getting the engine and transition re-conditioned. . That should cover most potential problems, not sure if Chris would be up for that sort of work. My overall target would be to get 250-300 bhp wich will obviously have implications for other components.
 
two left feet said:
Yep, 290 bhp with bolt-ons. Cams will be worn probably. (mine were worn (2002 model) enough to start throwing the rocker arms).
Torque will be a consideration. I had new Clutach and flywheel (Sachs) but now with over 500 nm, i get drive train "rumbles" if the revs are too low. You have to change your driving style a little. Chris currently uses the Garrett 2260 vk, which is a little laggy, but once you hit boost you think you are driving a S4....
Click to expand...
The old A** type heads need porting in order to get large turbos to spool decently, the gtb2260vk is a very good alrounder and very strong turbo nevertheless. As you've noticed on your car, with Bhp comes a lot of torque which is difficult to keep in check especially with large nozzles. Volumetric efficiency increase with tuning and exhaust mods so one gets a much more driveable car and a lot of bang per buck ! With tuning the first 50 Bhp cost a few hundred pounds and the next 50Bhp cost thousands ! In case of the v6 tdi it's quite a tuneable engine so getting over 100 Bhp for 2 grand is quite cheap...
 
nick75 said:
I'm spending the winter researching options and working out prices. I have read that the cams wear and it's something I've been looking at. I have wondered weather to buy another one to use as the project car. I am considering the idea of getting the engine and transition re-conditioned. . That should cover most potential problems, not sure if Chris would be up for that sort of work. My overall target would be to get 250-300 bhp wich will obviously have implications for other components.
Click to expand...
Best would be to bring the car to me, i would test drive it and then advise you what needs changing and what does not ! I don't like to beat around the bush but if it needs changing or mending i would advise you so ! 300 Bhp is hot hatch teritorry, the car will have to deal with a lot of torque which can bring a lot of driveline issues. As a minimum, some suspension arms, roll bars and brakes will need upgrading just to keep the car composed under stress ! Look forward to see you !
 
  • Like
Reactions: All-rod and opronnie
Read the thread a6 turbo chip, there are a few posts on the subject...
 
Tuning the v6 tdi is a good call to start with the exhaust. The precat and main 2x cats are very restrictive and the pipework is designed to create turbulence and back pressure. Going for a 3" exhaust downpipe splitting into 2x 2" or 2.5" pipes will release a lovely burble and also free up a few bhp. You just add larger nozzles, a hybrid turbo with modern internals or a modern turbo altogether and you tie it nicely with a clutch friendly remap ! Simples...
 
  • Like
Reactions: opronnie and nick75
Would all this just be an option on the manual gearbox version?
 
jimmp said:
Would all this just be an option on the manual gearbox version?
Click to expand...
Nope, the ZF gearbox in the auto version is very strong as well due to being conventional with a torque converter ! It will cope fine with 500Nm of torque + they can be made stronger with just a torque convertor upgrade ! All the above applies to automatics too however i have tried my mods on manual gearboxes as they can take the pounding without much issues !
 
adamss24 said:
Tuning the v6 tdi is a good call to start with the exhaust. The precat and main 2x cats are very restrictive and the pipework is designed to create turbulence and back pressure. Going for a 3" exhaust downpipe splitting into 2x 2" or 2.5" pipes will release a lovely burble and also free up a few bhp. You just add larger nozzles, a hybrid turbo with modern internals or a modern turbo altogether and you tie it nicely with a clutch friendly remap ! Simples...
Click to expand...
Really interesting thread. would like to know what this sort of added kit would cost to fit or to supply... i have an 05 allroad 2.5tdi with nothing done to it so exploring options...cheers.
 
Make a target of what you want and how much you intend to spend, recipe is simple: large turbo, large nozzles, remap and a few more supporting mods !
 
adamss24 said:
Nope, the ZF gearbox in the auto version is very strong as well due to being conventional with a torque converter ! It will cope fine with 500Nm of torque + they can be made stronger with just a torque convertor upgrade ! All the above applies to automatics too however i have tried my mods on manual gearboxes as they can take the pounding without much issues !
Click to expand...

Manual boxes react differently to added power, I would say you would either need a map with more low-end torque or gearbox remap too. Main issue is it upshifts sooner than before remap which is a problem in top gears unless you floor it or use tip mode.
 
Early cars with rocker arms had issues with poor oil changes especially IF mineral or semi synthetic oils were used ! Later cam rollers heads as fitted from 2003 on were less of a problem however i have rebuilt a few with cams issues following timing belt failures... The later B** series engines had hollow cams and they can still fail however the replacements from dealer were solid- machined from billet and were virtually unbreakable !
 
adamss24 said:
Early cars with rocker arms had issues with poor oil changes especially IF mineral or semi synthetic oils were used ! Later cam rollers heads as fitted from 2003 on were less of a problem however i have rebuilt a few with cams issues following timing belt failures... The later B** series engines had hollow cams and they can still fail however the replacements from dealer were solid- machined from billet and were virtually unbreakable !
Click to expand...

Ok, cool.. Thanks or clearing that up

So just to clarify, only the A*** (150/155hp) engines used rocker arms?
 
audi upgrades
All A** series engines had rocker arms, even the 180 Bhp ones... I have replied to your other post...
 
adamss24 said:
Tuning the v6 tdi is a good call to start with the exhaust. The precat and main 2x cats are very restrictive and the pipework is designed to create turbulence and back pressure. Going for a 3" exhaust downpipe splitting into 2x 2" or 2.5" pipes will release a lovely burble and also free up a few bhp. You just add larger nozzles, a hybrid turbo with modern internals or a modern turbo altogether and you tie it nicely with a clutch friendly remap ! Simples...
Click to expand...

Hi

Picked up this old thread while doing some research on Allroad issues. Looking to get myself a final edition 2.5 tdi. I had a 2.7t a few years ago till. Water in TVM started causing issues so looking at manuals only this time. Was interested to read about swapping out the exhaust pipes. When I get one, I'm not really interested in pushing 300bhp, more likely a remap and wondered if worth doing the exhaust upgrade as well. Can you make these up from Templates or do you usually need the ones off the car as samples?

Thanks
 
I have an 03 allroad with the AKE lump in it, what engine mods and what power figures can you get out of them safely ofcourse, I'm new to these v6's tia
 
You must log in or register to reply here.

Similar threads

D
A6 Allroad 2.5 diesel tuning
Replies
1
Views
2K
adamss24
A
C
Allroad 2.5 V6 - Tuning options & experience
Replies
5
Views
2K
fjtwelve
fjtwelve
M
a6 allroad 2.5tdi v6 2004
Replies
1
Views
1K
adamss24
A
M
Allroad Tuning Box
Replies
5
Views
2K
Torque and Caffeine
Torque and Caffeine
J
A6 Allroad
Replies
2
Views
1K
John C
J
Top
Back