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  #21  
Old 06-04-16, 21:09
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10 stallion 10 stallion is offline
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Default Re: T4 2.5 tdi race engine build goal 300 bhp+

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Originally Posted by slimjim View Post
Keep going down the route you are 10 stallion.

... and make sure you keep the updates, photos and images coming!
Thanks Slimjim If i can even help one t4 owner to decide the route he wants to go by looking at these pictures and give them the confidence to do it , then my job is done. This forum has helped me so much so thanks to you all..........

Luck favours the prepared mind
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  #22  
Old 06-04-16, 21:10
adamss24 adamss24 is offline
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Default Re: T4 2.5 tdi race engine build goal 300 bhp+

ARL pistons or 2.0 Tdi 8 valve will drop in with a bit of machining but i tend to use Crafter pistons as they are much, much stronger than the volvo or vw fitted jobbies...
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  #23  
Old 06-04-16, 21:13
kwempe kwempe is offline
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Default Re: T4 2.5 tdi race engine build goal 300 bhp+

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The old AFN engine used twin valve spring setup and a steel taller to stop the spring wearing a groove in the soft cylinder head. The AJM Pd115 rods are the next best thing compared to the stock VE rods but- as i did not compare the Volvo rods- i cannot tell for sure if they are any stronger ! The cracked rods were a technological leap and as mentioned above spread the load on the rodsand not on the bolts.
I always use the AFN inner springs in my builds and retain the outer springs however the aftermarket springs are a bit overkill in a daily driven motor.
I would suggest going with a modern GTB turbocharger, a gtb1756vk will be quicker on boost than the stock k14 turbo and sustain 2 Bar of boost without much bother and be happy at over 260 Bhp, however i would use a gtb2060vklr as it's just the best ball bearing turbo with lightning performance ! I have done many hybrids and some are really fine IF you choose components carefully but they are no match to a similar sized stock gtb turbo ! As i mentioned in many of my posts, i tend to use turbos less than 10 year old technology !
A ball bearing turbo would be lovely but the two biggest pitfalls are the lack of a T25 Flange and hence an easy to fit (an AXG) manifold and the prohibitive cost of that over a GT2260v with billet wheels and a 360 degree bearing. Obviously we would reconsider if you want to donate us one, just to try of course but we don't have access to a supply of secondhand vklrs.Whilst myself and Andy can both mig weld, tig is something we have yet to try so manufacture of our own manifold is some way off.
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  #24  
Old 06-04-16, 21:27
kwempe kwempe is offline
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Default Re: T4 2.5 tdi race engine build goal 300 bhp+

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Originally Posted by adamss24 View Post
ARL pistons or 2.0 Tdi 8 valve will drop in with a bit of machining but i tend to use Crafter pistons as they are much, much stronger than the volvo or vw fitted jobbies...
ARL pistons would be a bloody loose fit! 79.5 mm pistons in an 81mm bore? The 2.5tdi lump has the same 81mm bore size as the 2.0 tdi so is not quite a 1.9tdi with an extra cylinder...
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  #25  
Old 07-04-16, 06:41
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slimjim slimjim is offline
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Default Re: T4 2.5 tdi race engine build goal 300 bhp+

Lots of very interesting stuff there chaps!

Sorry for mixing up the Keith's!
Keith De Costa is the owner of United Diesel. He is the country's leading specialist in diesel fuel pumps and injectors.
Totally understand what he (and you kwempe) are saying about a 13mm. With providing pressure when you have larger injectior holes.
It's all about atomisation, which Keith@UD showed me in his workshop on the crazy testing bench setup he has. With good atomisation vs bad.





Very easy to get more fuel into an engine. But as I said before, smaller injections setup right, putting LESS fuel in... will always out perform larger injectors 'pouring' more fuel in with bad atomisation.
Yes, both WOULD be better, with a bigger pump but the main problem right now is I am struggling for air (need a bigger turbo, plans for that in this coming winter) so there is no point upping the fuel till the air can keep up.

When it comes to the valve springs, the only reason we replaced mine was because we were getting valve float.
Yes, this was at higher revs (over 4k) but as the power keeps going up there and I do go over 4k on 'spirited' gear changes. In a drag situation, it is hard not too. (Or on the street, for that matter!)

Might be something you want to think about anyway, as the Rostens are not that pricey and should you 'accidentally' pop over 4k, should stop your engine from cutting out. (Like mine did on the start line at Santa Pod, VERY embarrassing!)

I am by no means an expert just want others to learn from the real life T4 issues I had, if they want to.
No point in everyone making the same mistakes!

Last edited by slimjim; 07-04-16 at 06:47.
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  #26  
Old 07-04-16, 06:44
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slimjim slimjim is offline
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Default Re: T4 2.5 tdi race engine build goal 300 bhp+

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Originally Posted by adamss24 View Post
I always use the AFN inner springs in my builds ..... and sustain 2 Bar of boost without much bother and be happy at over 260 Bhp .... As i mentioned in many of my posts, i tend to use turbos less than 10 year old technology !
How many of the T4's you have built are running 260bhp+ Adamss24? Sounds like loads!
Very interested to talk to the owners about getting them into the T17.club.

Can you please let me know.....?
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  #27  
Old 21-04-16, 08:44
adamss24 adamss24 is offline
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Default Re: T4 2.5 tdi race engine build goal 300 bhp+

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How many of the T4's you have built are running 260bhp+ Adamss24? Sounds like loads!
Very interested to talk to the owners about getting them into the T17.club.

Can you please let me know.....?
To this date none apart from my own however i worked on loads of AFN,AVG,AHH engined a4 tdi which were souped up with large nozzles and larger pumps + more efficient turbochargers ! The principles are the same: more air and fuel into the pistons equal more power. The regular t4 owner is a quite mature owner with bit more sence than money so i did not spot much of a market there apart from the regular injector change which Rake and a few more tapped it before me !
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  #28  
Old 21-04-16, 10:17
norseg norseg is offline
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Default Re: T4 2.5 tdi race engine build goal 300 bhp+

Very nice, it makes me understand more.
gclub iphone
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  #29  
Old 23-04-16, 10:32
kwempe kwempe is offline
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Default Re: T4 2.5 tdi race engine build goal 300 bhp+

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Originally Posted by adamss24 View Post
To this date none apart from my own however i worked on loads of AFN,AVG,AHH engined a4 tdi which were souped up with large nozzles and larger pumps + more efficient turbochargers ! The principles are the same: more air and fuel into the pistons equal more power. The regular t4 owner is a quite mature owner with bit more sence than money so i did not spot much of a market there apart from the regular injector change which Rake and a few more tapped it before me !
Me and Andy are heading towards maturity but hopefully between us have just a little "sence" (sp), with our rubbish turbo using 10 year old + technology and having our hand forced at the last minute by a massive mechanical failure, we managed 16.54 at Santa Pod on the very first ever, gentle drive!

https://www.youtube.com/watch?v=GNPFg6gKhfg

Please excuse the profanities
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  #30  
Old 01-05-16, 14:13
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10 stallion 10 stallion is offline
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Default Re: T4 2.5 tdi race engine build goal 300 bhp+

Just testing the engine @ 211bhp at Santa pod on 30/4/2016 to work out which mods make the most difference to the bhp and were the restrictions are .We have found out that the intercooler is holding it back ,so that's the next mod FMIC....
When you watch the clip on you tube ,as the van goes down the track you can hear the air hunting up and down, still managed a 16.0621 pass though


https://youtu.be/2PU-hIug0ek

Luck favours the prepared mind
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