Garrett Turbos

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  • S2central.net
    Retired OG Mod
    • Jul 2003
    • 16590
    • Country: Northern Ireland

    #1

    Garrett Turbos

    Yep - a closer look at the Garret GT30R and GT35 confirms they are both viable for high boost applications on the S2/RS2 engines.

    Based on my calcs (from Corky Bell and other sources) I get a corrected airflow rate of ~48lbs/min at 7000rpm with VE=85% and Boost=1.8bar. That would need an uprated bottom end but the GT30R will *just* be happy with PR=3 without running into choke.

    The GT35R has additional headroom and could sustain PR=3.2 at this engine speed.

    Looking at the surge lines, assuming PR=3 from 4000rpm then the GT30R would be just OK - within surge limits, but the GT35R would definitely be unhappy with this condition - it is optimised for generating high PR values at high engine speeds only.

    So my gut feel appears to be about right with the GT30R being a much better choice for road use. It would sustain PR=3.2 between 4500 and 6000rpm.

    I'll write this analysis up properly sometime, but I'd like feedback from Marco, Mihnea and others on my brief summary here.

    For reference I am assuming Delta P across a good intercooler of 2psi and Delta P across the air filter of 0.5psi as per Garretts guidelines for calculating PR.

    I'd need a little more time on the spreadsheet to calculate a suitable boost profile on the GT30R so that it doesn't have surge problems at lower RPM.


    Paul

    PS - I'm lookng at the GT30R map for 700382-12 with the 56 Trim compressor wheel... I haven't got my head round the turbine wheel choices yet with regards A/R, but the 0.82 choice would appear to have less lag, so thats what I'd go for on a road car.

    Oh and the GT35R would appear to be better in a 2.5L application at first sniff. Evidence to follow sometime next week when I get plotting some graphs
    Paul Nugent
    Webmaster http://S2central.net
    Administrator http://S2forum.com

    1994 S2 Coupe ABY - aka Project Lazarus
    2001 A6 allroad 2.5TDi - family tank
    2003 S4 Avant 4.2 V8 - daily burble

    Purveyor of HomeFries and Exclusive agent for Samco hose kits (S2/RS2)

    There are only 10 kinds of people that understand binary - those that do, and those that don't
  • diesel des
    S2Forum Possessed
    • Feb 2004
    • 3896

    #2
    Originally posted by S2central.net
    Yep - a closer look at the Garret GT30R and GT35 confirms they are both viable for high boost applications on the S2/RS2 engines.

    Based on my calcs (from Corky Bell and other sources) I get a corrected airflow rate of ~48lbs/min at 7000rpm with VE=85% and Boost=1.8bar. That would need an uprated bottom end but the GT30R will *just* be happy with PR=3 without running into choke.

    The GT35R has additional headroom and could sustain PR=3.2 at this engine speed.

    Looking at the surge lines, assuming PR=3 from 4000rpm then the GT30R would be just OK - within surge limits, but the GT35R would definitely be unhappy with this condition - it is optimised for generating high PR values at high engine speeds only.

    So my gut feel appears to be about right with the GT30R being a much better choice for road use. It would sustain PR=3.2 between 4500 and 6000rpm.

    I'll write this analysis up properly sometime, but I'd like feedback from Marco, Mihnea and others on my brief summary here.

    For reference I am assuming Delta P across a good intercooler of 2psi and Delta P across the air filter of 0.5psi as per Garretts guidelines for calculating PR.

    I'd need a little more time on the spreadsheet to calculate a suitable boost profile on the GT30R so that it doesn't have surge problems at lower RPM.


    Paul

    PS - I'm lookng at the GT30R map for 700382-12 with the 56 Trim compressor wheel... I haven't got my head round the turbine wheel choices yet with regards A/R, but the 0.82 choice would appear to have less lag, so thats what I'd go for on a road car.

    Oh and the GT35R would appear to be better in a 2.5L application at first sniff. Evidence to follow sometime next week when I get plotting some graphs
    Paul thats pritty much what i had worked out. Peak boost and torque from about 4k. And happy at 2 bar of boost at 7+K rpm at the top end. I went for the same trim of comp you are talking about eg 56 with a Ar 0f 0.6 on the 77mm wheel compressor and the 0.82 ar turbine. I plan on useing it on a stock bottom end, and hope that with some cleaver Mihnea mapping it will stick together at 1.8bar boost at 7Krpm giving near 400BHP at the wheels or what ever Mihnea reckons is safe. Apparently its the low and mid range big boost and torque that bend the rods so with that limited the engine should just hold up.

    Obviously i will use a BIG intercooler and have 7a cams, tube manifold etc, etc. Ohh, its going in a URQ. thanks,des.

    Comment

    • salmon
      S2Forum Enthusiast
      • May 2004
      • 134

      #3
      Out of interest what is the standard turbo fitted to an S2.

      Been under mine today to fix the starter (which required a slight knock) and the only markings I can see are KKK?

      Comment

      • Greg_S
        Administrator
        • Jul 2003
        • 12430
        • Country: United Kingdom

        #4
        I believe it is a K24
        Greg

        S2Forum.com Administrator & Webmaster

        '93 Coupe with a few tweeks

        Comment

        • Beetie
          S2Forum Extremist
          • Oct 2003
          • 1517
          • Country: England

          #5
          Originally posted by Greg_S
          I believe it is a K24
          Correct mate!
          Was a '93 3B, Dont ask now tho......

          Comment

          • S2central.net
            Retired OG Mod
            • Jul 2003
            • 16590
            • Country: Northern Ireland

            #6
            Originally posted by diesel des
            Paul thats pritty much what i had worked out. Peak boost and torque from about 4k. And happy at 2 bar of boost at 7+K rpm at the top end. I went for the same trim of comp you are talking about eg 56 with a Ar 0f 0.6 on the 77mm wheel compressor and the 0.82 ar turbine. I plan on useing it on a stock bottom end, and hope that with some cleaver Mihnea mapping it will stick together at 1.8bar boost at 7Krpm giving near 400BHP at the wheels or what ever Mihnea reckons is safe. Apparently its the low and mid range big boost and torque that bend the rods so with that limited the engine should just hold up.

            Obviously i will use a BIG intercooler and have 7a cams, tube manifold etc, etc. Ohh, its going in a URQ. thanks,des.
            Good luck with that on the stock bottom end. I'd fear for the integrity of conrods at 1.8bar at 7000rpm myself. Have you done the fuel calcs yet ?
            Dunno for sure if green injectors are up to that spec with the S2 or RS2 fuel system - you might need a Bosch mosport pump and 5bar FPR. Failing that Mihnea can source some HUGE sized injectors for you if needed...

            Let us know how you get on with the GT30R !
            What EM are you planning on using - the 'S1' from MTM or something custom ?

            Paul
            Paul Nugent
            Webmaster http://S2central.net
            Administrator http://S2forum.com

            1994 S2 Coupe ABY - aka Project Lazarus
            2001 A6 allroad 2.5TDi - family tank
            2003 S4 Avant 4.2 V8 - daily burble

            Purveyor of HomeFries and Exclusive agent for Samco hose kits (S2/RS2)

            There are only 10 kinds of people that understand binary - those that do, and those that don't

            Comment

            • Mihnea
              S2Forum Extremist
              • Jul 2003
              • 1288
              • Home: Belgium Current: United Kingdom

              #7
              Des, Paul:

              On a stock bottom end, I won't ever exceed 1.7 Bar peak and 1.3 at 7000 RPM with such a compressor, never ever!!! Even though it might not make a peep hole in the block in the first 10k miles, it's not safe and will wear your engine out very quickly.

              If you really want to use the potential of that turbo, get a good set of rods, all new bearings and check all clearances, drop the CR a bit (I'd say around 8:1 is ideal), Bosch motorsport fuel pump, 4 Bar FPR, big injectors (I have 440cc@3Bar available, at 4 Bar rail pressure they do supply 510cc/min) and then we have a shot for a monster engine that will remain pretty reliable...

              But on the stock bottom end and compression ratio, I'm sure we'll have to drop boost in order for the engine not to ping like a church bell before anything else...


              Cheers,

              Mihnea
              '98 Silver Grey 2.7T S4, dual 2.75" turbo back exhaust with no cats, FMIC, BIG injectors, 10 Bar motorsport fuel pump, modded RS4 turbos, tubular exhaust manifolds, custom intakes, RS4 MAF, Bilstein PSS9, H&R ARBs, 19" BBS CH, custom remap, 511 BHP/505ft-lbs

              www.MRCTuning.com
              info@MRCTuning.com
              Workshop Directions

              Comment

              • Pisobiker
                S2Forum Extremist
                • Jul 2003
                • 1175
                • Country: Finland

                #8
                Originally posted by S2central.net

                .....I'll write this analysis up properly sometime, but I'd like feedback from Marco, Mihnea and others on my brief summary here.

                ......

                Looks correct to me.




                Marco

                Comment

                • S2central.net
                  Retired OG Mod
                  • Jul 2003
                  • 16590
                  • Country: Northern Ireland

                  #9
                  Cool Marco - whats your thoughts on a VE assumption of 85% for the stock engine across the rev range ?

                  WOuld a sweetly polished head like MarkH's take the VE to 90% or better - whats your gut feel ?


                  Paul
                  Paul Nugent
                  Webmaster http://S2central.net
                  Administrator http://S2forum.com

                  1994 S2 Coupe ABY - aka Project Lazarus
                  2001 A6 allroad 2.5TDi - family tank
                  2003 S4 Avant 4.2 V8 - daily burble

                  Purveyor of HomeFries and Exclusive agent for Samco hose kits (S2/RS2)

                  There are only 10 kinds of people that understand binary - those that do, and those that don't

                  Comment

                  • diesel des
                    S2Forum Possessed
                    • Feb 2004
                    • 3896

                    #10
                    Originally posted by Mihnea
                    Des, Paul:

                    On a stock bottom end, I won't ever exceed 1.7 Bar peak and 1.3 at 7000 RPM with such a compressor, never ever!!! Even though it might not make a peep hole in the block in the first 10k miles, it's not safe and will wear your engine out very quickly.

                    If you really want to use the potential of that turbo, get a good set of rods, all new bearings and check all clearances, drop the CR a bit (I'd say around 8:1 is ideal), Bosch motorsport fuel pump, 4 Bar FPR, big injectors (I have 440cc@3Bar available, at 4 Bar rail pressure they do supply 510cc/min) and then we have a shot for a monster engine that will remain pretty reliable...

                    But on the stock bottom end and compression ratio, I'm sure we'll have to drop boost in order for the engine not to ping like a church bell before anything else...


                    Cheers,

                    Mihnea
                    Mihnea , you are the man i hope to map my URQ with this combo when finished. Dont worry, it will be a while yet. It takes a Looooong time to save up the cash . I plan on using those big injectors you talk about etc. But i had read from some of your posts that with all the right bits added to say a RS2, eg, turbo, tube manifold, injectors, cams, intercooler, exhaust etc, BUT a sotck bottom end you could chip to 400BHP easy. Is this wrong? I will be running a Gt 30R, Rs tuning manifold, 7a cams, big intercooler, big exhaust, your injectors all in a aby in a URQ. I will run the car for fast road use and track days, not every day, but i will super unleaded 97 ron at least. It must last some time, not just a day, but not 100K miles though. What do you reckon is safe boost wise, torque and Bhp? Whats that bhp at the wheels on a 016 box? I could add a shim to the head to lower the Compression ratio, but am worried about stuffing up the squish and getting more ping. What do you think? This month i am geting the manifold, next moth some parts from you i hope. One part at a time. Thanks, des.

                    Comment

                    • Pisobiker
                      S2Forum Extremist
                      • Jul 2003
                      • 1175
                      • Country: Finland

                      #11
                      Originally posted by S2central.net
                      Cool Marco - whats your thoughts on a VE assumption of 85% for the stock engine across the rev range ?

                      WOuld a sweetly polished head like MarkH's take the VE to 90% or better - whats your gut feel ?


                      Paul
                      Paul, I think you might have been a little pessimistic regarding VE. Actually our 4 valves heads look quite good to me, but, of course, not having flow charts of any kind it's not possible to tell.
                      I think, anyway, on OEM or RS2 camshafs, VE might go up to 90% in the midrange, while at top rpm it might actually drop a bit.

                      Let me say that the lower the OEM VE the better it is.....

                      Yeah, thas right, I'm not crazy (.... err..... maybe slightly... ):
                      the lower the OEM VE the highest the gains obtainable with porting and polishing + optimizing intake and exhaust layouts. If our heads already produced lets say 98% VE, than any effort on raising it, no matter how much money and how many ours on the flowbanch, would only produce very small gains.

                      If some of the "high performance" guys here would like, there is a pretty easy test I can think of to check VE differences while upgrading bits:

                      1) Disconnect WGFV plug so that boost will be fixed at the 0.6-0.7 bar "safety mode", without the ECU being allowed to mess up the outputs while trying to eventually compensate flow increases with boost changes... ;
                      2) Dyno test your car with the original setup;
                      3) Install new head;
                      4) Dyno test your car again (always with WGFV unplugged).

                      All other parameters must stay the same (same dyno banch, ext temp, barometric pressure.... etc.) so that % hp gained approximatly shows effective % increase in VE.

                      Do the same test with any other intake/exhaust mod.

                      ..........


                      Increasing VE and flowing efficiency of IC and inlet ducts is of course very effective in any high boost application (in my opinion anything above 1.5 bar boost is the case).
                      As a matter of fact compressor is probably working in a "mid-to-low" efficiency area, therefore transferring a lot of heat to the charge. Any imporvement in the inlet to compressor (air filter, MAF, MAF to compressor duct) which will affect P1, and any improvement in the IC + ducting + IM + head flow, will allow at same IM boost to run lower compressor P2/P1 ratios, therefore having denser charge (more power) and cooler charge which allowes more aggressive ignition timing (more power again).


                      Marco

                      Comment

                      • Jamo
                        Retired OG Mod
                        • Mar 2004
                        • 21750
                        • Country: United Kingdom

                        #12
                        Paul, did you ever investigate the GT28R suitability to the S2?, i ask because this seems to be very popular with the Fiat Coupe's 20V turbo's

                        Comment

                        • S2central.net
                          Retired OG Mod
                          • Jul 2003
                          • 16590
                          • Country: Northern Ireland

                          #13
                          Funny enough - I recommended EXACTLY that turbo to someone I met recently who owns such a car - I checked out the compressor map against that application and it looks good.

                          As for suitability to the S2 - I'd say no 'cos that Garrett turbo has an integral wastegate - as opposed to the superior external WG that we all have.

                          Paul
                          Paul Nugent
                          Webmaster http://S2central.net
                          Administrator http://S2forum.com

                          1994 S2 Coupe ABY - aka Project Lazarus
                          2001 A6 allroad 2.5TDi - family tank
                          2003 S4 Avant 4.2 V8 - daily burble

                          Purveyor of HomeFries and Exclusive agent for Samco hose kits (S2/RS2)

                          There are only 10 kinds of people that understand binary - those that do, and those that don't

                          Comment

                          • audiman
                            S2Forum Freak
                            • Jul 2003
                            • 4827
                            • Country: United Kingdom

                            #14
                            Des, sounds like you combo will be putting out somewhere in the region of 370bhp @flywheel. With the bottom end stock it wont take it. Boost will be limited to 1.7-1.8 and will have to tail off to about 1.2 at redline. Shimming the head is one way, but that wont last. Either skim pistons or buy custom ones. and replace the rods. Its the only way. I have bent a rod at 1.8bar. And thats with boost low at top end!
                            sigpic
                            Tom C - www.rcmr.co.uk
                            Audi UR Quattro
                            Audi 100 C3 2.0 5 cyl 115ps
                            Audi S2 - 07k engine project aiming for 800ps
                            Audi B5 RS4 645ps 911nm

                            Comment

                            • sal_s2
                              S2Forum Extremist
                              • Jul 2003
                              • 1287
                              • Country: United Kingdom

                              #15
                              So is the gt35r out of the question?
                              If I used one of these, what would the characterisics of the engine be?

                              Comment

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