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2.5TDi V6 quattro Sport 180hp Turbochip

Discussion in 'Diesel forum' started by fjtwelve, Jan 13, 2006.

  1. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    The fuel tank pump is almost brand new, replaced just before you got it. Is the allroad pump bigger?
  2. adamss24
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    adamss24 Well-Known Member

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    Been chasing a vacuum leak lately, replaced vacuum pump, new N75, all vacuum hoses, blanked EGR valve,etc. In the end i traced-it to the intake flap solenoid- disconected-it and presto- full boost again ! Nice to do 45-48Mpg again !

    Also fitted a top upper strut brace from a sports a6 1.9Tdi 2003 model, i was so surprised to find this did not have it fitted from the factory, now it turns in sharper and has less body roll. Also new Eibach 32mm front antiroll bar with poli bushes- this made the car less grippy but corners a little more flat, cannot be bothered to take it off for time being, i will probably revert back to stock jobbie soon.

    Also got itchy feet again, been offered a tidy sum for it by a few people so i might put it up for sale, however i wish i keep the engine and put it in something more sporty, a b5 quattro perhaps or a late b6 tdi quattro !
    To get more power out of it reliably would mean getting a stronger clutch (reinforced rs4 or Sachs SRE) and possibly a new DMF or a single mass altogether ! In this tune the clutch does not slip regardless of how i drive it but turbo does not work at it's potential !

    Also need to sort the slight idle shudder, been offered +60% larger nozzles than stock which are plug and play on the AKE/AFB engines but without the misfire at iddle, i might get a set just in case and try them on !
  3. HerefordQuattro
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    HerefordQuattro Member

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    keep it!
  4. adamss24
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    adamss24 Well-Known Member

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    I wish mate, thing is my ABT allroad is back from bodyshop, i also have a 180 Bhp t4 transporter, a 2004 allroad tdi auto, a b6 1.9 tdi avant(tuned to 220 Bhp), 2x b6 v6 tdi quattro saloons + 4x b5 audi's a4(petrosl and diesels) and i just bought another 2004 1.9 tdi quattro b6 saloon with a Quattro GMBH/sline bodykit !
    Just sold a 1.8TQS and a passat tdi estate...
  5. adamss24
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    adamss24 Well-Known Member

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    Took a ride in a standard b5 rs4 avant last night and i can safely say that the a6 would blow it's doors off to 120Mph ! They say never meet your idols !!!
  6. blackwagon
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    blackwagon Member

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    After installing the R683's and a 3 bar MAP sensor I have the same problem, when doing 1/4mile sprint the engine dies of fuel starvation, which is murder on the VP44. It sounds as exactly the same phenomenon as you described. I think the (tiny) in tank fuel pump just can't keep up under these circumstances. I only see one option to cure this, a decent lift pump like the Raptor airdog which should deliver plenty of juice AND keep the VP44 cool and well lubricated. The GTV 2559 is waiting to get installed, but more air will do no good as long as we are running out of fuel.
  7. adamss24
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    adamss24 Well-Known Member

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    Not much to report apart from being stopped twice by the plod- need to sort out the smoke issue. I think the pre-cat is sooted-up and is a restriction as every once in a while i get it to run better after i take it for a spirited drive on motorway ! Just got a set of s6 lower door trims which i will get color codded and i also aquired a pair of BDG cam roler heads which i am porting and i will replace the hollow cams with solid, genuine camshafts. Working a AKE 2.5 tdi engine with oversized pistons, 2.0 CR tdi pistons and 3.0 petrol crank, should be quite something with 500cc increase !
  8. blackwagon
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    blackwagon Member

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    Hello,

    Aren't you running the custom exhaust fjtwelve had made for the car ? He had already ditched the soot filters if I remember correctly ?
    Wow, hold on, I don't think you can install the solid AKE cams in a BDG or BDH head, the profiles are specific for the roller rockers, it won't work. I also did the BDG conversion, runs smoother, quiter, I think the only way to keep those rockers in place :)

    That sounds interesting, 2.0 C.R pistons and 3.0L crank. Which engine is the crank from ? does it need mods ? Which conrods do you plan to use ? What about the piston bowl and injector spray angle ? Much to take into account :) I would be very interested to know details and discuss the problems and search for solutions here.

    I'm going to install water/methanol injection on my AKE shortly

    B.R

    Stefan
  9. blackwagon
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    blackwagon Member

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    Hello,

    I finally found a few hours to tinker on the A6.
    The idle shudder due to the big bosio r683 drove me insane, also moving on and off the throttle when rolling wasn't 'clean'
    The problem is the idle stability control that can't cope with the r683's, undershoot,overshoot ... you can see this happening with vagcom under 'engine' measuring blocks 013 and 014.
    I made a little metal bracket with adjustment screw that allows me to adjust the gaspedal travel so that it doesn't fall back to 0
    % but stays at 1,8% with pedal released. This eliminates the idle control and also the shudder ! Secondly change the adaption value for the idle speed as low as possible with vagcom. Rocksteady and smooth 960rpm idle ! This is a little more than the stock 780 but it is a hell of a lot better than the violent vibrations and the lubrication of the cams was never ideal under 1000rpm.

    B.R

    Stefan



    Aren't you running the custom exhaust fjtwelve had made for the car ? He had already ditched the soot filters if I remember correctly ?
    Wow, hold on, I don't think you can install the solid AKE cams in a BDG or BDH head, the profiles are specific for the roller rockers, it won't work. I also did the BDG conversion, runs smoother, quiter, I think the only way to keep those rockers in place :)

    That sounds interesting, 2.0 C.R pistons and 3.0L crank. Which engine is the crank from ? does it need mods ? Which conrods do you plan to use ? What about the piston bowl and injector spray angle ? Much to take into account :) I would be very interested to know details and discuss the problems and search for solutions here.

    I'm going to install water/methanol injection on my AKE shortly

    B.R
  10. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    Pleased to hear you fixed this. I was sometimes able to eliminate the shudder by applying a tiny bit of pressure to the accelerator pedal (it's mentioned above somewhere) but as did not have vagcom was not able to fiddle with the settings.
  11. adamss24
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    adamss24 Well-Known Member

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    Sorry for late reply, did go on a long holiday which meant putting projects on the side. Anyway, the solid AKE cams work in BDG/BAU/BDH heads, i have rebuilt 2 allroads so far with messed up hollow cams. If anything, they feel more powerfull as i reckon the solid cams have a tiny bit more lift compared with the hollow cams. Anyway, they drive fine 1 year on since conversion, i still used the cam roller and lifter assembly as they are particular to the heads.

    Just started to pull the engine, the clutch is slipping so i cannot even do a boost log properly + had loads of things i bought for it stashing in the shed: new DMF, Sachs Race Engineering clutch, larger hybrid turbo, facet posiflo lift pump and much more !

    The new engine is almost ready to drop in but i don't have much time...
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  12. adamss24
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    adamss24 Well-Known Member

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    Sachs SRE pressure plate with rs4 clutch disc:
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    one reason why hollow cams are rubbish:

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    damage they do when the rings break:

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  13. adamss24
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    adamss24 Well-Known Member

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    Update: i have been building a v6 engine for a while then a mate had his BDG engine chew a cam so i offered my old engine as a swap ! So the new engine is a BDH 180Bhp with ported heads, new stem seals , thicker head gaskets, new solid camshafts (genuine audi) and much more. Won't go into much details as there are a few custom mods which should get it going like stink !
    Anyway, the old clutch was slipping-the spanner monkeys that fitted it did not reset the pressure plate hence not clamping properly-plenty life left in the clutch and old flywheel. New LUK flywheel, new Sachs SRE 3 pieces clutch, full cambelt kit and water pump,etc.
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  14. adamss24
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    adamss24 Well-Known Member

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    All up and running, the new engine is less smokey than the last one and pulls just as hard ! The old engine was a little quieter though... Blown a boost hose on the test drive whilst doing a boost log. The actuator still needs tweaking but it's back to former self ! Very pleased and the new sachs clutch grips very well and not hard on pedal at all ! Will update the thread with pictures later on...
  15. adamss24
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    adamss24 Well-Known Member

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    Car needs mapping now, the turbo is capable of much more but i had to de-tune in order to stop the clutch from slipping. The a6 is deceptively fast ! Need to monitor the fuel consumption now, the new engine is not as aggressively ported than the old one which should be better on fuel at low speeds but it does not have the same top end as before ! The passat i've fitted my old lump in was completely different beast, only limited by the original injectors- they are too small !
  16. adamss24
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    adamss24 Well-Known Member

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    Took it out for a spin and my god it scares me ! The clutch has a little judder and the pedal is getting slightly harder to press but it holds whatever i can throw at it ! Sending the original map to a chap who's s*it hot with tuning the v6, then i will take it to a rolling road session ! I'll keep you posted with the results...
  17. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    Sounds good let me know when the map is sorted and i'll bring the 535 down and you can do some back to back tests think i know where my money is
    We passed 150000 views. Unbelievable.
  18. adamss24
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    adamss24 Well-Known Member

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    Took Alex, a mate that also has a v6 tdi allroad and he's brother in law has a 535d, he reckons the a6 is faster and puts the power on the road much, much better ! We were swapping turbo's in order to do a back to back comparison: same injectors, same car and different turbo settings and i found the Turbo Dynamics hybrid had a poorly adjusted stop screw, which would explain the poor performance after 120 Mph ! Winding the stop screw a couple of turns back made a lot of difference, however i need to use a EGT/EMP gauge to set it right properly. It's very easy to screw a turbo with a miss-adjusted stop screw !
    So far i am really pleased with the outcome, the car still needs a few bits to make it entertaining enough to me but it ticks most boxes and i like the "sleeper" look !
    Yeah, 15000 views is a lot, been a long thread this !
  19. AlexGSi2000
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    AlexGSi2000 Well-Known Member

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    Wow, lots of development going on here! Love it. :w00t:

    Wish I lived closer to London! Wouldnt mind someone breathing over my AKE.
  20. adamss24
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    adamss24 Well-Known Member

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    I have a couple of turbos with bigger compressors and turbines, they are all low mileage, freshly rebuilt ! I have to fit them to the car in order to get the actuator and stop screw set-up properly as there is no factory setting for hybrids ! Larger nozzles and a 3bar map sensor a good remap should see you close to 250-270Bhp ! That's a lot of fun in a car over 1500Kg !
  21. adamss24
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    adamss24 Well-Known Member

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    3 plunger pump head and bigger distributor block:
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  22. doktorec
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    doktorec Member

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    Now with this mods it depends how big is your turbo and how big are the nozzles.I think you can hit 330-340 with big nozzles and big turbo.
  23. adamss24
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    adamss24 Well-Known Member

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    Bosio race nozzles are about 80% bigger than standard, however i still cannot get rid of the smoke under 2000 rpm's on my car ! The biggest hybrid that fits in the stock housing is gt22 turbine and 66mm compressor wheel, however the response suffers a little unless you don't mind a little lag ! With a gt25 turbine housing you can fit a billet compressor wheel up to 70mm in size but we are talking lag in 10's of seconds now !
    Last edited: Aug 27, 2013
  24. adamss24
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    adamss24 Well-Known Member

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    Had a look at the pump a few days ago and unfortunately it looks like never been changed, most likely it's the original pump that was supplied with the car ! The reason why i think it's the original as there's too much dust on top of it and loads of scratches which will be content with an old item...someone punched the power supply cables with an electric probe at some point in order to check it's working or not.
    Anyway, i have a lift pump now in there, not tested the car on full throttle yet, i have a few coolant leaks on the "new" engine + a bit too busy with work but getting there !
  25. doktorec
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    doktorec Member

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    If 80% is not enough call me to give you +130%.66 compressor on 2.5-2.7 bar will give you 350hp.What more do you want.If you don't like lag put another gtb1749v as a HP turbo.
  26. adamss24
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    adamss24 Well-Known Member

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    Hi fellow members, just swapped the race 683 nozzles (which were fitted to AKE injectors) to AFB injectors and no more idle shudder and i have a steady 3.5Mg/stroke injected quantity at idle! Best mod i have done so far ! Only thing to do is swap the needle lift injector plug to the AFB one, it's square compared to the round one from AFB. The nozzles dropped in, no pop adjustment required and the injectors are very nicely balanced when monitoring with VCDS in measuring blocks 13/14 !

    Now i need to sort the tune again and start injecting fuel gradually below 1800rpm's to get more torque in, the clutch holds nicely although is a little juddery and i did not bed it in yet !

    I knew the AFB injectors will work as i have the power plus 683 nozzles fitted to another set but with pop pressures raised to 260 Bars, they are a bit noisier but the fuel economy increased a little- they are fitted to my other allroad which i use primarily for towing ! I will get a new set of race 683 nozzles and swap them and report back with results, this nozzles have been sent to diesel specialist for balancing !
  27. adamss24
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    adamss24 Well-Known Member

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    Well, so far so good, however i have a few issues with the car, for some reason the engine is ok from cold then it gets funny when hot, it feels like turbo lag but it's not ! No fault codes but the power delivery it's either on or of and the pump is barking a little. As a side effect it looks like the engine does not shuts down anymore on a drag race so no worries there, but i worry the pump might be on last legs or the tune is completely wrong and it does not dump enough fuel to get the larger turbo spooling ! No smoke whatsoever although i can make it smoke if i step on it !
    Need to sort out the map this weekend, i will start with a fresh original map and adjust it as required. I will keep you posted !
  28. adamss24
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    adamss24 Well-Known Member

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    Decided to flash a new map from a similar age sports v6 tdi and start from scratch, I started to have weird issues with Celtic Tuning map especially from hot, flashed the original map and the smoke came back ! Fortunately the idle is steady even with the smoke so i decided to adjust the tune a little at the time and tune by smoke limiter and add more boost at low revs... So far i am injecting 50% less fuel under 1800rpm's and i just ordered a 4 Bar boost sensor- will have that fitted next week so i will report with results !
    Clutch is holding nicely and not a hint of slip even at WOT !
  29. adamss24
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    adamss24 Well-Known Member

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    After flashing a couple of maps and playing with SOI and smoke limiters i have a half decent car to drive. Bought a 4 Bar MAP sensor from Darkside but forgot to click the option for the reducer sleeve so i need to wait a couple more days for the part to arrive.
  30. adamss24
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    adamss24 Well-Known Member

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    Fitted a nice little hybrid tonight, it's a hybrid spec with a Bmw turbine and a mercedes compressor wheel and it's a very, very nice little turbo to drive ! It made the old barge fun to drive again !!! I only tried it as the VNT in this was set on a flow bench so it's good to use out of the box ! Took a few pictures but i hit the bandwidth limit on my photobucket !

    I did hit over-boost though, the 3 Bar MAP sensor is saturated so needs upgrading ! I am also waiting for a hybrid gtb2266vk which has been sent to Darkside Developments for VNT conversion and modification so that will go on the car in a few weeks along with a full 3" downpipe and some silicone hoses...

    I am itching to get that engine into something smaller, however sorted the c5 chassis is it's not match for the power- too much weight to haul around !

    Funny thing is too of my mates have bought a6 tdi's quattro and they keep asking me for specs on how to tune their cars !!!
  31. adamss24
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    adamss24 Well-Known Member

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    Rocking this little beauty for a while whilst i am waiting for a hybrid gtb2260vk from Darkside Developments and the 4Bar map sensor... The turbo might not look much but spools instantly and the compresor wheel is able to push 300Bhp with a larger turbine and more efficient housing on it's native 3L Mercedes engine ! Need to take it to a 4 wheel dyno to see what it pushes at the moment ! Here's a few direct links for pictures:
    http://i840.photobucket.com/albums/zz323/adamss24/DSCF5471_zpsaf89754f.jpg
    http://i840.photobucket.com/albums/zz323/adamss24/DSCF5472_zps96043439.jpg
    http://i840.photobucket.com/albums/zz323/adamss24/DSCF5470_zpsa425916c.jpg
  32. adamss24
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    adamss24 Well-Known Member

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    4 Bar map sensor fitted today along with a pair of new front drop links and new front brakes ! Unfortunately the 4 Bar map sensor is putting the car in limp mode- the voltage MAP needs re-calculating as the car is now in "limp mode". Also got the gtb2260vk back form Darside and what a fine job they did- not cheap but very, very nice ! Waiting for the weekend to fit it so i can mock up the 3" downpipe so i can remove the pre-cat !
    Also bought a pair of 20" tyres to fit my s8 alloys, i will be fitting 8.5" wide on the front and 9" wide wheels on the rear...should look sick ! Also swapped the single DIN for a double din and RNS stereo/sat nav...need to fit the rest of the rs6 interior !
  33. darysas
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    darysas New Member

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  34. adamss24
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    adamss24 Well-Known Member

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    4 Bar MAP sensor linearization made by a friend of mine so the car is back to former self ! I will spend a few hours tomorrow to finish welding the 3" downpipe to mate with the gtb2260vk which is converted to vacuum ! Will let you know how it is in a few days !
  35. adamss24
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    adamss24 Well-Known Member

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  36. adamss24
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    adamss24 Well-Known Member

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    More updates ! Managed to fit the 4Bar map sensor and have it re-calibrated then i took off the last turbo i have on the car- getting a gtb2260vk which is converted to vacuum (might have that hybridised with a billet compressor wheel if it works nicely out of the box!) then managed to mock up the 3" downpipe so it's ready to weld and mate with the rest of the exhaust. Also bought 4 tyres to use on my spare set of 20" audi s8 wheels, fronts are 8.5" wide and rears are 9" wide with an offset of 45mm and 46mm respectively ! The 8.5" fit nicely on the front but they will need probably a 5 or 10mm spacer to clear the upright, the rears need a min of 10mm spacer to clear the strut. Bought 4x 225/35/20 Falken tyres so i do hope they work properly on the car ! Few pictures for the record !
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  37. doktorec
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    doktorec Member

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  38. S4_dan
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    S4_dan Fire up the Quattro!

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    Wow. Some serious power there Chris! Watching this thread as once christmas is out of the way and Timing belt/waterpump in November, I'll be looking to tweak my A4 2.5 AKE. I'm sure there will be plenty of questions to ask!

    Dan
  39. adamss24
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    adamss24 Well-Known Member

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    S8 w12 alloys wrapped in 225/35/20 Falken 452 rubber and 10mm H&R spacers fitted all round... The forged 20" wheels are lighter than the stock 17" wheels and it picks up speed rather quick ! Ride is just a bit bumpier and the front tyres need balancing... Front brakes are looking tiny behind 20" wheels !
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  40. matthew999
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    matthew999 Member

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    Looking very tastey there Chris. I would love to get some 20s on the barge!

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