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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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    [May 29, 2009]
    Found that the vacumn hose off the N75 had split at the end so nipped it off and put it on again. The car is going very nicely but i have just had to put a litre of oil in it after 1200 miles oh buggrit
  2. mikeya4
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    mikeya4 Member

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    [May 29, 2009]
    any of you know what the 2.5 boosts at standard?
  3. V6 Quatt
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    V6 Quatt Active Member

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    [Jun 9, 2009]
    :icon_thumright:Yeh me too would like to know the 2.5 TDI capablities.

  4. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Jun 15, 2009]
    Guiseppe Bosio finally replied to my emails. He says" I think you need RACE 683 ( or powerplus 683) if it's the 6 cylinder engine ( original power should be 150 or 180 hp). IMPORTANT: do not use anything else apart from 683 number otherwise you destroy the engine (spray pattern is different). " I have a UK contact now which i am following up. I may start with the pp683 whilst looking for the turbo and fmic, and then trade up to the Race 683s later and sell the pp683s on. Depends how much it costs and how useful/knowledgeable the UK guy is.
  5. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Jun 16, 2009]
    Anybody used Unichip/Dastek for diesel tuning? If so how did you get on? They have been mentioned as a possible remap system for tying together the mods i have described.
  6. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Jun 16, 2009]
    Bosio powerplus 683 nozzles £276 for 6, Jeremy Lear at Lear Automotive based in Norwich lear.automotive@yahoo.co.uk, 0044 1603 722 597. :yum:He is ordering TODAY so be quick, in stock next week (Italians allowing). From what i can tell he knows his stuff. Tell him i sent you so i can get some discount....
    GT2359V turbo as fitted to Mercedes C320 CDI AMG 230HP can be supplied by Owen Developments for the knockdown price of £1254.73. :faint:Form an orderly queue so we can get some discount......Adam Roberts adam@owendevelopments.co.uk
  7. quattrojames
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    quattrojames Moderator Staff Member Moderator

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    [Jun 16, 2009]
    So you're going for new injectors, new turbo and then a remap to tie it all in together?
  8. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Jun 17, 2009]
    er, back at the top of the page i more or less said: nozzles only not injectors, fmic if required (looking for someone to calculate whether or not the original intercooler will cope and if not how big the replacement needs to be), turbo if i can fund it, remap to replace chip if i find someone who is familiar with the combination of parts.
  9. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Jun 18, 2009]
    I've PM'd the Dorset man, lets see if he replies.

    The GTB2260VK is fitted to the current Audi 3.0TDI engine,. Everybody i speak to says it will spool up quicker than the 2359 due to its size, but may not deliver the peak power. (Ball bearing turbos spin up faster anyway, and apparently clever shaping of the vanes cause less restriction in the exhaust flow too).That may not be a problem for me as i am only looking to go to around 250hp. If it blows hard enough for the 3.0litre engine than hopefully it will be enough for my 2.5 litre lump.

    I am now in touch with someone in Europe who is quoting around 60% of the above price for the 2359, and less for the 2260.
  10. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Jun 22, 2009]
    Couldn't resist this picture. Check out the badging.....
    [​IMG]
  11. quattrojames
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    quattrojames Moderator Staff Member Moderator

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    [Jun 22, 2009]
    Lol, we were just discussing yesterday having an A4 4.2 TDi ;)
  12. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Jul 8, 2009]
    Still waiting for my nozzles. Have found Celtic Tuning in Roche near Newquay who can take on the work. Going to go for a hybrid turbo as this will involve minimal work to manifolds. Intend to dyno run as is, back to standard, Celtic remap, Celtic remap with nozzles. Probably need to save up for the turbo and fitting, but Celtic say they will only charge dyno time to remap.
    I'm good at planning, lets see how reality goes.
  13. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Jul 13, 2009]
    Finally Parcelforce realise I live in a house and not the flats next door
    [​IMG]

    Thats an awful lot of money for a very small bit of metal. Anyway on we go
  14. quattrojames
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    quattrojames Moderator Staff Member Moderator

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    [Jul 13, 2009]
    Is it all starting to fall into place then?

    Dammit you're going to win at the 2.5 RR day at this rate!
  15. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Jul 14, 2009]
    Remapping exercise booked in at Celtic Tuning in Roche near Newquay for 9am Saturday. Celtic say that should deliver 215-220hp based on their R&D at Powerstation in Tewkesbury. Having said that everybody says they get about 210 - 220 hp from a remap, its the driveability i'm bothered about. We'll drive around for the weekend to see how that goes, then if its all ok the nozzles will get fitted and re-mapped again next week while i'm in sunny Dublin and then we'll see how that is. If its all OK I may offer my wife a trip to see her brother who lives in .... Tewkesbury.....where i'll just pop down to the garage for a few minutes to get a like for like comparison.
    The turbo is going to need a few extra shillings so it'll be sometime in August for that one.
    I am not going to modify the exhaust but if i did then Turbo Dynamics estimate the hybrid turbo nozzles free flow exhaust and remap are estimated to be good for 280-300hp.
  16. quattrojames
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    quattrojames Moderator Staff Member Moderator

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    [Jul 14, 2009]
    Excellent, let us know how the remap goes on Sat and the power you get before changing the nozzles :thumbsup:
  17. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Jul 15, 2009]
    Alan Jeffrey in Plymouth has a 4 wheel rolling road, i'm trying to get in there on Friday afternoon before 530 to get a baseline figure for "as is" with the Turbochip, and back on Monday for a Celtic figure. I 'll ask him if he's interested in a session for the 2.5tdi's. What with flying to and fro Dublin and working double shifts this is starting to get like a top gear challenge.
  18. quattrojames
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    quattrojames Moderator Staff Member Moderator

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    [Jul 15, 2009]
    Lol, put a first class stamp on the car and it will get there on time :lmfao:
  19. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Jul 18, 2009]
    Even though they lost my luggage i got to Plymouth in time. First dyno run was ****, 163hp, hmm, lets unplug the MAF, second run no difference. New MAF on order this morning comes Tuesday so i'll be back Thursday afternoon for another go and we'll try again next Friday morning before i'm off again (for a change i'll be off to Glasgow). Audi Tresilan said this is a brand new MAF for 90 quid plus VAT, the old exchange price was about 85, have Audi been listening to their customers?
    This probably explains the variability in performance i've been experiencing, but because i don't drive the thing often enough at the moment i hadn't pinpointed it. Should have listened more to Jim at Star when he thought the MAF might be dodgy when i dynoed it up there last year after the Heathrow Engines debacle, and it only made 180hp. I was putting it down to HE.
    Just occurs to me that i'm describing 163hp as ****, have i got the right perspective here? Ah who cares lets make it go faster
  20. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Jul 27, 2009]
    New MAF no difference. Car with Celtic for a diagnostic this week. Could be a temperature sensor.
  21. quattrojames
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    quattrojames Moderator Staff Member Moderator

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    [Jul 27, 2009]
    It's pain all this, hopefully the diagnostic will throw some clues your way.
  22. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Jul 30, 2009]
    "We have gone right through the diagnostics and also checked through for vacuum losses etc and can not find a single fault... we have cleared all the errors off the ECU as there was an array of them, including the MAF sensor which you previously had fitted. It has picked up low down and removed a lot of the hesitation but I would be reluctant to say its got the power back."
    I'm trying to get back to the dyno tomorrow to see what we've got.
  23. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Aug 4, 2009]
    Couldn't get to the dyno due to my flight being delayed 3 hours. Fair play to Graham at Celtic who sat with my car at Newquay until 630pm waiting for me.
    Anyway he's right about the low down response, it is better and cleaner, but its all less than it was before, and past 3000rpm theres not a lot happening. I've given him copies of all the dyno curves to date to see if he can suss anything out.
  24. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Aug 10, 2009]
    Back to the dyno last Friday, 168hp second run, a tad over 270ftlb, smoother curve, but obviously something wrong still. And just to show the seat of the pants needs recalibrating there is very slightly less power and torque than before up to 1400rpm. Was going to leave the car with Celtic for the remap today but as the entire population seems to be driving around Cornwall and crashing into each other this week i was delayed and only just made the flight.
  25. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Aug 17, 2009]
    Just come back from Germany visiting my mate with 2007 A6 Avant 3.0TDI running nearly 400hp with remap, no other mods, goes like stink. 260-270kph anyone? (Thats 161-167mph in real money) Think my next car might be going on holiday to Germany.
  26. Turkster
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    Turkster Bro.Paul 2.5TDI Quattro Sport

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    [Aug 18, 2009]
    i dont think your 2.5 will go that fast, 135mph is a rough idea where it will go to, but let us know,
  27. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Aug 19, 2009]
    I've already had 143 on the sat nav.....
  28. quattrojames
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    quattrojames Moderator Staff Member Moderator

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    [Aug 19, 2009]
    With 400bhp I would think 160mph is a very realistic prospect!
  29. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Aug 20, 2009]
  30. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Aug 31, 2009]
    Part 189. We now have a Celtic remap. I've only done about 150 miles so far. The old Turbochip map seemed to have somehow corrupted but we can't see how, Celtic said the computer was asking the turbo for a large (up to 0.37bar additional boost) but not adding enough fuel, result is the turbo may have been getting toasted by the high exhaust temperatures. I was starting to suspect the turbo was dicky albeit for different reasons.

    There’s significantly more torque up to 3000 and the pick up from a standing start is smoother and quicker, starting around 12-1400rpm. You can hear the engine starting to growl a bit too. It now revs its head off in the lower 3 gears like it used to (as in whoops that was about 5500rpm) but possibly more quickly. It is pulling better through to 4000 or so, but not completely fixed, slows a bit in 4th and the old surge in 5th and 6th that destroyed the 90-120 range is not back yet. I haven’t been able to do a top speed run yet. It is beginning to look as if the recent poor fuel economy might be better too but it’s a bit early to tell for sure. Definitely on the right track though, I’m in danger of starting to grin when I put the foot down.

    I’ll get back to the dyno on Friday hopefully and go back to Celtic on Monday for fitting the new nozzles and remap for them during the week. I have read that the seating washers for the injectors are best replaced at the same time.

    Hybrid turbo is definitely to follow now given that the currrent one could be worn. I am hoping, or more accurately the bank manager will be, that the turbo is not too far gone to rebuild.

    The other good bit of news is Heathrow Engines are being wound up
  31. quattrojames
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    quattrojames Moderator Staff Member Moderator

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    [Sep 4, 2009]
    Good, sounds like you are getting somewhere at last. I will be interested to hear what the RR figures say :)
  32. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Sep 8, 2009]
    Hilarious. We are now at 170hp/3800rpm and 285ft lb/2200rpm, almost standard (177hp and 273ftlb, can't remember rpms). Curve pretty well reflects seat of the pants description above. Had a talk with Celtic this morning and agreed there is no point fitting the nozzles until the turbo is replaced. Trying to get tech spec for hybrid at the moment. Probably 2 weeks or so away. Fuel economy has perked up though, back to where it was too, but with only one tank full though a bit early to be certain.
  33. adamss24
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    adamss24 Well-Known Member

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    [Sep 8, 2009]
    I would take the rocker covers and look for missing lifters as there is no way you could lose soo much power. Turbo is a turbo, if it does not wistle then it should be ok. Either is a boost leak somewhere( split intercoolers) leaky clips or a faulty n75 then it should perform as it should. Could it be that the map is not suitable for the engine ? Where you got the nozzles from ? Interested in a set for me own also how much the hybrid turbo is gonna cost ? Regards, Chris.
  34. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Sep 9, 2009]
    Find it hard to believe lifters are bust, they were only replaced at Christmas using VAG parts and my mileage this year has been miniscule. I do get a whistle, one of the symptoms of my N75 failing before was that the whistle disappeared. Have searched for leaks and found none. N75 will get replaced at same time as hybrid turbo. Nozzles from Lear Automotive, see my post 16th June above. All prices will be posted as i get them. On this subject the 4WD dyno runs at Alan Jeffrey in Plymouth are £50+VAT. Celtic will probably book some dyno time to fine tune the remap the nozzles and hybrid, don't know cost per hour yet.
  35. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Sep 14, 2009]
    The car is now at Celtic to have the turbo exchanged with a Turbo Dynamics hybrid, the nozzles fitted and the computer remapped. Celtic have priced this at £1200 for everything, including what they've done to date.
    Of this the exchange turbo is £795+VAT. If my turbo is goosed beyond exchanging TD had previously quoted me £1195+VAT for a new part. Spec sheet attached below

    If all goes OK (that'll be a first) then I get the car back Friday.

    I have to say that the service i have had from Celtic to date has been very good, they've put up with finding the continuing problems, missed appointments, taxiing me to the airport and so on. Recommended.

    VAG – 180 BHP

    Hybrid Turbochargers

    Garrett Turbochargers – Part No 454135-0010 – Aircooled

    VAG Part No. – 059145701S - 2003->


    APLICATION : Audi A4/A6/A8 Vw 2.5/ 2.8TDI - 180BHP


    Stage1

    MD438

    Brief Specifications: -

    Stage 1 – MD438

    Hi flow GT20 compressor wheel, cnc machined compressor housing, 360 degree thrust bearing, cut back turbine blades, lightening of turbine wheel for faster ‘spool up’, modified V.N.T. turbine housing, uprated turbine seals. Other ‘blueprinting’ modifications. APPROX 280-300 BHP

    Please Note: This application needs exact engine management settings, up-rated injectors, free flow exhaust system to achieve these horsepower figures.

    Please note: - All specifications are for reference purposes only and are subject to change by Turbo Dynamics Ltd. without prior notice. All boost pressure recommendations are subject to engine condition and preparation. Modifications to the engine can affect the performance and reliability of the turbocharger and the related performance figures. For further information please talk to our technical staff who may refer you to one of our recommended tuners.

    Options: - All the above turbochargers can be special order and at extra cost, if not part of the standard specification. One off specifications and turbo matching also available.


    Retail Price List


    TypePart No. Current List Price – Brand New Units

    Stage 1 MD438 £1045.00

    1. All prices are in Pounds Sterling (UK), net ex-works and supersede all previous prices.

    2. All prices are subject to VAT at the current rate.

    3. Turbo Dynamics Limited reserves the right to revise, change or modify part numbers, specifications and prices of listed items without notice.

    4. The listing of a price for a particular part number does not guarantee availability.
  36. adamss24
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    adamss24 Well-Known Member

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    [Sep 15, 2009]
    Any news on the progress ? Would love to see your car as i am planning to fit a v6 tdi 3.0L turbocharger and Iveco nozzles onto me a4 2.5 tdi quattro...this winter ! Also, is there anyone who could build a better inlet manifold ? Had a heavily tunned v6 tdi a4 quattro with a rare 3L block, AKE heads + injectors and a PSI Power Box wich was really,really fast ! Sold it and i am missing it ever since !
  37. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Sep 15, 2009]
    Turbo should have been couriered to TD yesterday and i haven't heard its shagged out yet.
    I'll be at Newquay Airport around 330 Friday, assuming all has gone well Graham from Celtic will be meeting me there with the car. If it hasn't i'll be the one hiring a Corsa for the weekend, or wondering what i need to replace next as the new turbo still hasn't fixed the power loss. I'm assuming you want a go in it not to look at it.
    I considered the route you are going but ditched it in favour of what is essentially a series of bolt on extras giving about 100hp/60ftlb for about £1500.
  38. adamss24
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    adamss24 Well-Known Member

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    [Sep 15, 2009]
    You bet i wanna drive-it ! For the time beeing, looking at your modded car/engine:hubbahubba: will do !
  39. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Sep 17, 2009]
    Turbo comes back Friday so car won't be ready til next week. TD have confirmed the body is OK for the rebuild but made no mention of the internals so still don't know if there was a problem or not. Rocker covers off for nozzle replacement, nothing broken in the valve gear.
    Don't think looking at the engine will reveal much difference from standard. The car is remarkably unmodified externally, all the money has gone into it not on it if you get me. I'll spend money on prettifying it once the main view people get of it is the back end of it disappearing rapidly into the distance....
  40. fjtwelve
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    fjtwelve Moderator Staff Member Moderator

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    [Sep 17, 2009]

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