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HOW TO - Turbo your 2.4D!

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2.4d turbo conversion
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#23 ·
all sorted now , got new oil pipe from vw with 16mm 1 end and 12mm the other (mine was 12mm both ends )
just waiting for me intake hose to arrive and hopefully im in the turbo gang
thanks for the in depth guide it helped me a lot
cheers
mattyT:
 
#24 ·
Great job and thanks for the detailed pics. Funny I seached and finally justed posted a "looking for" thread and only then found your 2.4 Turbo thread after, on exactly that question! My 94 2.4 Diesel seems perfect for the turbo.
Questions:
1/Is there a techincal reason why the 2.5L Intake mainfold is better? apart from proximity to the rear mounted Turbos outlet?
2/ Why no intercooler? My thought was by plumbing the Turbo's Outlet downwards to a grill mounted intercooler like those used on Volvos (infront of the Radiator) which exits the cooled air out on the upper passenger side which would then be close to the stock 2.4L diesel intake manifolds intake port..a intercooled system could be created using the stock Intake manifold? Thoughts?
3/ You have preset the boost at a particular setting, but did you consider a manual wastegate control, like those used on aircraft, with a push pull control cable in the cockpit? As mountain driving situations with an altitude increase can really lower performance as the ambient airpressure decreases (especially at higher temperatures) so a manual boost allows you to "normalize airpressures" to sea level equilvalents +plus what ever extra boost you elect to add at your own descretion.. watching the pressure guage.
3/ What about changes in injector sizes or types, to accommodate the turbo? Was anything needed or tried there?
4/ I didnt see any comments about the change in performance? Was it noticeable and how would you summarize the improvement? Worth doing?
5/ One last note and suggestion about control of the wastegate - adding an EGT exhaust gas temperature sensor and guage is a great tool for monitoring the engines heating, overheating and fuel burn situation.

Hope thats not too many questions! Looking forward to your reply
Cheers :ILU:
Dirk from Ontario Canada
 
#25 ·
Interesting to note, from here in Canada, the right hand drive differences. Such as placement of the brake boost system, which on my Canadian model t4 is on the opposite side of the firewall. Yet the Coolent tank is on the same side as yours... So I wonder if the exhaust manifolds are completely different or not? I'll find out and post it FYI.
Also, for my camper/ Baja 94 T4 project I removed the huge stock air filter barrel box and plumbing, and installed a simple K&N cone type airfilter right over the stock intake sleeve with one band clamp, (where it first comes out of the intake manifold). Leaving new room for a second Battery box and a second starting battery, which I diverted all non-starter accessory feeds to. Then I changed the stock Bosch Altenator for a 350 amp dual rectifier alternator. # CS144-DR350 National Quick Start Sales www.alternatorparts.com about $509.95 us$
Routed to the dual starter batteries in the engine compartment, and to the dual deep cycle batteries in the camperized interior, with battery isolators. Finally, the Deep Cycle system is connected to a 3000 watt inverter with a large Capacitor in between, to handle initial power start up surges, creating a full 110volt power system that is capable of handling everything from mig welders to airconditioners, while the engine is running. This includes using a roof top RV Air Conditioner while driving (in the desert!) instead of having an engine mounted automotive A/C style unit. With shore power plug in the whole system can also run off an extention cable plugged into wall outlet or RV park when available. Baja Style Surf Van! More to come!
 
#26 ·
http://www.tidytransporters.co.uk/product/vw-t4/t4-performance-parts/vw-t4-2.5-tdi-intercooler-kit/

FYI: An intercooler kit for 2.5L TDI, which might also work for the 2.4 TDI project. Of course any intercooler from any turbo system could be plumbed in, custom.
I see that the VW 2.5TDI engine is also used in the Audi 100 and a6 and various 1990's vintage Volvo's and other VW's had 2.5 TDI's certain years, like the Passat. Does anyone know if any of these and if so which of these might be used as a parts source for the 2.4 project? For example are the intake and exhaust manifolds compatable?
 
#29 ·
hi there, i have followed your post religiously and now have a turbo 2.4, but how much do i wind the actuator up, i have wound it up a fair bit and got to 0.3 bar and i dont really notice any difference in performance, just the nice wurr of the turbo...am i being a wuss lol

regards
james:confused:
 
Discussion starter · #31 ·
DirknCanada said:
Great job and thanks for the detailed pics. Funny I seached and finally justed posted a "looking for" thread and only then found your 2.4 Turbo thread after, on exactly that question! My 94 2.4 Diesel seems perfect for the turbo.
Questions:
1/Is there a techincal reason why the 2.5L Intake mainfold is better? apart from proximity to the rear mounted Turbos outlet?
Using the 2.5 is tried and tested and anything is better than the bunch of bananas currently in there lol
2/ Why no intercooler? My thought was by plumbing the Turbo's Outlet downwards to a grill mounted intercooler like those used on Volvos (infront of the Radiator) which exits the cooled air out on the upper passenger side which would then be close to the stock 2.4L diesel intake manifolds intake port..a intercooled system could be created using the stock Intake manifold? Thoughts?
I have an intercooler just not fitted yet, people run higher spec engines without so dont think its an issue
3/ You have preset the boost at a particular setting, but did you consider a manual wastegate control, like those used on aircraft, with a push pull control cable in the cockpit? As mountain driving situations with an altitude increase can really lower performance as the ambient airpressure decreases (especially at higher temperatures) so a manual boost allows you to "normalize airpressures" to sea level equilvalents +plus what ever extra boost you elect to add at your own descretion.. watching the pressure guage.
Altitude driving isnt an issue for me in the uk, so presetting the boost wasnt an issue, ill tweak it up more once i have the fuelling better
3/ What about changes in injector sizes or types, to accommodate the turbo? Was anything needed or tried there?
Personnaly never tried any different injectors, there seems to be very little information on this
4/ I didnt see any comments about the change in performance? Was it noticeable and how would you summarize the improvement? Worth doing?
i never had any actually data of before and after only that it 'drives' better and well worth the money doing it, people will spend far more on 'Bling' than something as practical as this..
5/ One last note and suggestion about control of the wastegate - adding an EGT exhaust gas temperature sensor and guage is a great tool for monitoring the engines heating, overheating and fuel burn situation.

Hope thats not too many questions! Looking forward to your reply
Cheers :ILU:
Dirk from Ontario Canada
Click to expand...
Hopefully that answers a few questions Dirk.....
I am far from an expert in Diesel tunning in fact apart from plugging in a unit on my old vectra i have never messed with a Diesel before, what i am trying to do is document everything i find or do so that it may help others....
Next on the list is to get a used pump and set of injectors and play with those...Hopefully a 'How to ' on the fitting of an LDA to pump, and im going to strip the pump down first and have a play with a set of injectors too...
As the vehicle is the only one i have access to and is a daily driver it needs to be on the road, so all jobs are weekend only or the holiday periods.....

Soon to have yet another convert as Moodyblue has just secured the parts needed go 'TURBO'......
 
#37 ·
Hey guys looking for a bit of advice in relation to fitting turbo to 2.4D engine. Firstly my 2.4D engine code is AJA, however engine cover has AAB stamped onto it.

Secondly I have sourced a 2.5 TDI blue i van 88bhp engine code AJT which is breaking and I can get all parts, turbo, inlet and outlet manifold and all ancilliary pipes cheap.

My question is this. Is the turbo and manifolds the same on the AJT and ACV engines?
Will I be able to use these parts to fit onto my AJA engine.

Most info I have found seems to relate to AAB engines with ACV prts fitted.

Thanks:*
 
#40 ·
Thanks for the words of encouragement Stu, I'm going for it, got a Turbo, inlet and hopefully exhaust off a 102 ACV motor On the way


Still got a few bits to get before the cover comes off the Camper, but can't wait to get started on it now T:
 
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