Turbocharging an N/A engine

[PRY4SNO]

Cool project, and I applaud the idea of doing the brain work before the building. It takes a lot of time, but in the end it's worthwhile. And you learn a lot too.

When I was doing the specs for my build, a tuned k04 b5s4 was my target to beat. Spent quite a bit of time online reading, watching videos and using the BorgWarner MatchBot. From what I could gather, 60#/min is about the target I was looking for, so that equals ~GT30r size turbo. After much research and comparison, I chose an EFR7163. Hope that helps.

What car is the motor going into?

[Jack4688]

Gearbox is fine.

I would like to believe you but when the 01A DWR was used in a vehicle with 177bhp and 180lb/ft how can I be sure it will take 100 of each on top of those figures? If Audi did a longitudinal version of the BAM engine and it used the same drivetrain as the AJL then maybe it would be safe but it just seems a big leap to me and assume everything will be fine

Injectors?? Higher fuel pressure regulator?? Management??

Haven't looked into the fiddly bits yet, but for management I will speak to AutoMark in North Yorkshire and see what they suggest. I don't know if a Passat ECU can be sufficiently modified to run with forced induction or whether it'd have to be an aftermarket ECU.

[Jack4688]

What car is the motor going into?

Either my B5 quattro sport as it's a good base for a brown sleeper - and it all stemmed from me being bored of that engine, both power and sound.

Or, if I'm not satisfied the transmission can take an extra 100hp and 100lb/ft, I may look at doing the swap on a B5 S4. It would have to be under about £4k and either a dark colour to help fade into the shadows or I'd get it vinyl wrapped, most likely the same colour as my 1.8T and I wouldn't want to be messing about with removing a beige interior or walnut trim On the plus side a B5 S4 already has the brake setup I want and I know from clutch back it is all rated by Audi as being suitable for 265hp and 295lb/ft.

[sandman1111]

Plenty of 01A gearboxes manage with more power going thru them. I´m running an old 01A gearbox, no idea what power levels are, maybe 250 kW. My friend runs 01a on 4.2 v8 turbo. He is rwd, but still it holds up. I know a few other guys running 01A, with near 200kw. If it is not going to see launches with slicks, I´m sure its fine. That gearbox probably has open differential front and rear? So there isn´t mega grip to brake stuff You can always change the transmission later, if it becomes a problem. I won´t change my transmission until it brakes.

[Jack4688]

But which version of the 01A? I thought the 01A is simply the name for a family of 5 speed, longitudinal, four wheel drive gearboxes? Mine is the DWR version and I can't find any other use than the 1.8T A4, possibly equivalent A6s. I do agree with you that I'm not doing anything that'll put a lot of stress through it such as launches and I can always replace it if it breaks. Electronically locking diff? Or was that just reserved for the S4 and RS4?

[sandman1111]

All running old gearboxes from b3, b4 generation. Older versions of what you have. Don´t think there is any 01a, that is much stronger then other, they are all quite same . There is a thread in here, where it is estimated, that around 350 crank hp is where they will start to give up (01a gearboxes, not mentioning any codes).
You got front differential inside the gearbox, for driving front wheels. Some gearboxes had torsen, and most were open. And the rear is open also. So basically if you have open differential your gearbox only drives 2 wheels. 1 on front and 1 on back.

[Jack4688]

Are the different codes for ratios etc? My initial thought was that the 3B has a 5 speed, it must be the same as my A4. 3Bs are remapped to 260bhp and probably close to 290lb/ft without issue, ergo my 01A will cope. But then my mind started to unravel and I thought it would be best to find out for sure.

[Jaswan]

Which version of the VR5 are you looking to use? 10 or 20v?

I have a 24v VR6 in my coupe. when i was looking into what to change etc I read many many threads and stories saying 500 WHP was about the safe limit of the stock engine (When I say stock I mean head spacer and ARP Head studs)

I personally have went for rods, APR main, rod and head studs, coated bearings, and a head spacer in the VR6 with the intention of possibly building a more "built" engine later.

You would certainly need a larger turbo that a Ko4, (i presume you mean from a 1.8t? or is it from something like a vxr or something?) 1.8ts run out of steam never mind a 2.3.

presuming that most things are the same between the VR5 and VR6 I think a standard motor, with a head spacer and head studs would be happy with upto 350 WHP.

and as said building a manifold would be the hardest part. but you can buy pre made 5 port merges, and you could probably find a head flange online. Or take a gasket to a machine shop? i am cheating with mins a little and using the cast manifolds and a Y pipe to the turbo.

just my penneth worth

Jase.

[Jaswan]

Just thinking of management too, you would probably need to speak to a few tuners, possibly Stealth Racing about getting a base map on the ecu and then take it for mapping?

[Jack4688]

K04 was just a guess at something suitable, I haven't started to decide what my turbo should be. I've had many thoughts on this that and the other but only engine internals is what I've properly look into so far.

What kind of power and torque have you got from your setup?

[Error404]

Good old faithful K24 7000 will be perfect for 280hp on a 2.3 - reliable, cheap and plentiful

[Jaswan]

My coupe is still in peices.

But the last engine my turbo setup was running on was a standard 24v vr6 with headstuds and a spacer at it made 450 at the wheels on 1bar boost.

There is a vr5 on the vortex with a k16 ttrs turbo.

Jase.

[Jack4688]

Were the head studs simply because of needing extra length due to having a spacer? Or do the head studs need to be beefed up with the addition of forced induction?

[macspring]

http://www.carlicious-parts.com/epages/62028049.sf/de_DE/?ObjectPath=/Shops/62028049/Categories/%22V5%20Tuning%22

This link / web site may be of interest you as part of your research. When the site is viewed using Google Chrome it can be viewed in English as opposed to the original language of German.


No connection to it or cannot recommend it either way, just found the page / site while surfing.

Kind regards.

[Jack4688]

Yeah I found that last week, but thanks anyway