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2.4D AAB Turbo Project

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2.4d na 2.4d turbo conversion
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#621 ·
hi guys or is that'' van gods'' :cool: just wondering if any of u that have done ur turbo up grades did a bit of old school on ur cylinder heads ie gas flowed them.I did this many years ago on me mini's an it does make a difference to those gasses flowing through and as i have a spare cylinder head i'll be doin some fine polishing on those inlet an outlet ports I: .I'm planning on doing my 2.4 turbo upgrade this year after i rebuilt top end of my buzz 2yrs ago with steel head gasket an prob go for a L200 intercooler as they lot cheaper than vw but much the same,i must take my hat off to you guys for such an adventerious transformation on a wonderful engine,may the 2.4d live long an strong T: :cheers
 
Discussion starter · #622 · (Edited)
4x4phil said:
hi guys or is that'' van gods'' :cool: just wondering if any of u that have done ur turbo up grades did a bit of old school on ur cylinder heads ie gas flowed them.I did this many years ago on me mini's an it does make a difference to those gasses flowing through and as i have a spare cylinder head i'll be doin some fine polishing on those inlet an outlet ports I: .I'm planning on doing my 2.4 turbo upgrade this year after i rebuilt top end of my buzz 2yrs ago with steel head gasket an prob go for a L200 intercooler as they lot cheaper than vw but much the same,i must take my hat off to you guys for such an adventerious transformation on a wonderful engine,may the 2.4d live long an strong T: :cheers
Click to expand...
Jon T4 had his head off and did some flowing and porting on it , my head hasn't been off so i havn't .
JonT4 said:
It was only today that I realised how little I know about diesel engines! The heads on diesels don't have valve chambers like on a petrol and so cannot be reworked. The ports still can however. I had a play with the exhaust manifold today. To give you an idea of the kind of restrictive steps that are present I took a pic. The first shows the step on one port and the other shows the step removed prior to polishing.
Image

Image


These steps are restrictive on the inlet manifold, exhaust manifold and both sides of the head.

Brookster: Are these guys running 2 gaskets one on top of the other?
Click to expand...

JonT4 said:
Just to update on my progress; my head is ready to go back in. Will just have to sort out an issue with the oil feed connection and it should be ready to rumble. The head has been ported and polished on both inlet and exhaust ports, the valve guides have been removed, the seats have been cut with multiple angles and the face cleaned up, the turbo has been fettled and chamfered (done after this photo) and both manifolds ported and matched.
Image
Click to expand...
My Golf 16v has a fully flowed and ported head with wild cams and Throttles bodies but that's a NASP and makea big difference T:

I my opinion the 2.4D is a good solid engine with alot of potential with some old school Turbo tuning :D

We are going to Dubfreeze this weekend if anybody else is going so we can have a good chat about conversions
 
#623 ·
You need to be very careful when messing with the head on a Diesel as its not like a petrol where flow is king. A diesel head needs swirl in it to mix the fuel etc, if there is not sufficient swirl it wont mix properly and the van will just smoke like a chimney and no amount of mapping will cure this.:eek:
I have learn't this the hard way by having to buy a new head!!. It is not as though i tried a home job myself, i paid a lot of money to have this done by a highly respected in my area race engine builder.


After i had these problems i did a lot more research and basically the general consensus is that there maybe only one or to people if that) in this country that actually know and can be trusted porting a diesel head.

If i were you i would be very careful before taking metal out and smoothing it all of to much as you may end up like me having to buy a new head which isn't cheap believe me!.

Cheers.:ILU:
 
Discussion starter · #624 ·
Also when you have a Big Turbo pushing the Gases through there is no need to modify the head T:

As shown on JonT4's head he's just port matched the Exhaust manifold to the head.

A few of my friends running 20V Turbo BAM engines in their Golfs are getting Big power (600bhp) from standard heads and cams with GT35 Turbo.

Turbo specification is the critical choice in my opinion :D
 
#625 ·
I agree with you, some good points made there.T:

I have also gone back to a std cam as for my needs there is no need to move the power band up the rev range, i understand in race vehicles it can be a good thing but IMO not needed on a road vehicle.


Anybody want to buy a flowed head and custom high lift cam. LOL:LOL:


Cheers.:ILU:
 
#630 ·
Its the Volvo KKK K14 (b). Had the full works done to it by AET turbo's. It kicks in at about 1700rpm, pulls well for what it is. Looking forward to start mapping again as i think my smokey head was holding things up before. Also fitted an extra Earls oil cooler so should help things a little as the oil temp was getting a little to hot last time,:eek:


Got to get the interior finished before i can start driving it properly again as it is completely empty inside at the moment.
 
#631 ·
Hi, that made awesome and very interesting reading A:
I would just like to ask what sort of price would we be looking for to do a conversion like this? i know it depends on what deals/prices for parts but a rough idea before i get too interested in converting mine T::ILU:A:
 
#632 ·
soansey said:
You need to be very careful when messing with the head on a Diesel as its not like a petrol where flow is king. A diesel head needs swirl in it to mix the fuel etc, if there is not sufficient swirl it wont mix properly.
Click to expand...
Exactly right. The 2.4D is an indirect engine so doesn't have swirl chambers machined in to the inlet ports like the 2.5TDi so it is easier port. I have ported and polished the head completely but as said the key here is to create a turbulance to mix the fuel mixture prior to entering the cylinders. This can be done by carefully porting around the raised channel in the inlet ports and retaining the original shape and also the surface finish on the inlet side is very important. I also increased the injector pressures to improve fuel atomisation. Although the inlet side of a turbodiesel engine isn't hugely critical, don't forget that the exhaust side is still important. It doesn't matter how how quick you fill the cylinders they can't refill until they are empty so exhaust porting and surface finish is still vital to a quick smooth engine.
 
Discussion starter · #633 · (Edited)
Upgate -

Just done the first long a 200mile round trip to Dubfreeze and back since the conversion T:

The Van drives great and on a few steep hills pulled great up them in 5th Gear , thats the steep hill just before you get to the Showground you'll know which one i mean.

The Oil Pressures were fine the only Thing was the Oil Temperature cruising @ 65mph it stays at 95deg but @ 80 mph on the motorway it goes upto 120deg . Water Temperature is fine.

So the next job will be to fit a 12 row Oil Cooler , to give me a twin Oil coller set up like i have on my Golf . I will also fit remote Oil Filter like the Golf too this should keep the Oil Temperatures arround 100deg no matter how hard i drive it. :)

Existing Golf 12 row Cooler
Image


Existing Golf Remote Oil Filter Set up
Image


i will mount the existing Water Cooled Oil cooler on the remote filter mount. This set up will also increase the Oil capacity.
 
#635 · (Edited)
I took a quick vid tonight of the acceleration of the van in 5th gear to see how smooth it was from off boost upto decent revs. Although as you can see from the vid it's slightly uphill but it still shows how well a 2.4D can accelerate in 5th gear alone.

Excuse the low quality of the vid, the wrong date and the music (it was on the radio!) Honest...

http://www.youtube.com/watch?v=0KHHbeejBEI&feature=youtu.be
 
#636 ·
JonT4 said:
I took a quick vid tonight of the acceleration of the van in 5th gear to see how smooth it was from off boost upto decent revs. Although as you can see from the vid it's slightly uphill it still shows how well a 2.4D can accelerate in 5th gear alone.

Excuse the low quality of the vid, the wrong date and the music (it was on the radio!) Honest...

http://www.youtube.com/watch?v=0KHHbeejBEI&feature=youtu.be
Click to expand...
That is very impressive, a non turbo would take several minutes! I know I have one....!
 
#637 ·
johnnyblaster said:
This seems to be the way to go think I'll be the next to have a go only thing is I do vapour and sandblast so can make it look like I brought all brand new lol
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there is a full kit ready to fit on evil bay at the moment go on you know it makes sense you can have a look at mine if you want you are only down the road. where do you do blasting as i am poss looking to have my alloys done
 
#638 ·
Hi lads,

Does any one know if it is possible to fit an oil catch can to the AAB engine to stop the oil gunk build up in the intake manifold? Does this engine have Positive Crankcase Ventilation? Just researching for the parts I am ordering for the conversion and wanted to know if it was needed or beneficial.

Cheers Jerry
 
Discussion starter · #639 ·
T4PickUpOz said:
Hi lads,

Does any one know if it is possible to fit an oil catch can to the AAB engine to stop the oil gunk build up in the intake manifold? Does this engine have Positive Crankcase Ventilation? Just researching for the parts I am ordering for the conversion and wanted to know if it was needed or beneficial.

Cheers Jerry
Click to expand...
Yes you can fit a Catch Tank T:

Removing the EGR & Fitting a Catch Tank will reduce inlet charge contamination from Oil and Soot
 
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