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I bought my T4 888 special new almost 18 years ago. It’s been my daily work van all these years and shows no sign of giving up.
Early last year my son and I started overhauling it rather than looking to buy new just to avoid emissions charges in London (cheaper to advertise for work outside of London).

After following many accounts on the T4 forum I contacted Ron Goodfriend - Project Power. Top, TOP bloke! I wanted to restore our work van to be a strong build with reliability in mind but also an entertaining drive.

We went for his PP1 injectors, The first of his latest PP GTRS?-Hybrid turbo, 2.5” Downpipe and full stainless exhaust system. Ron has never failed to provide an enormous amount of help and advice as our project has evolved. As workload dictated that we couldn’t continue our build at leisure Ron introduced us to Tim (RT Sport in Ellesmere) who installed the turbo, downpipe, injectors, an oil change and a clear some old fault codes in time for us to drive back home the following day. Tim knows his T4’s inside out and is a genuinely decent bloke.

As a short nose T4 (the better looking one ?) I wanted to avoid all the cut outs needed in the front panel to help make a front mount intercooler effective (and we want the option of installing a/c in time) so we bought the top mount IC from a 102 T4 caravelle.
On Ron’s advice we then got hold of an AXG air box and MAF which we later found out needed to be mapped in.
I have to say that this combination without mapping... sounds pretty amazing on idle and by that I mean a race cammed V8 ??.

At some point during our journey I was introduced to Mario Burley in Telford..... (... actually no, I’ll leave it there. You probably know). I Now FINALLY have a larger top mount intercooler that could cope with the increased flow from the turbo when mapped. As time moved on this actually proved quite a capable unit.

As you would expect, just as we were ready to map and... the fuel pump starts marking its territory. PROJECT POWER teamed up with Central England Automotive (yet another introduction from Ron) and all was well.

Between the lot of them and the Shropshire Holiday inn, steak and beer were consumed while T4 engine running perfection was achieved. PROJECT POWER turned a really pristine fuel pump rebuild round in record time and Daz at #ceautomotive - Without question the most skilled perfectionist of a mechanic that has worked on my van during its 18 years and John an excellent cut and re-weld of the intercooler mounting points when new engine mounts meant we couldn’t get the bonnet shut at 4:30pm.

While in for the fuel pump Daz also located a boost leak to the intake manifold gasket so we had the intake manifold thoroughly cleaned out too (can’t recommend that enough after an EGR blank). He pinned down a boost issue to the N75 (Moo) valve and replaced that. Castrol Edge engine oil change. Castrol Syntrans gearbox oil change. New diesel injector run off pipes, manufactured a better fitting intake pipe from MAF to turbo inlet and sorted a couple of cab electrical niggles.

Next stop: Bobby Singh Racing, Windsor for its remap. REALLY interesting result - Its been mapped but not put on a rolling road for the final figures yet. Why? Well it turns out that in conjunction with BSR settling on the AXG MAF (rather than the AJT one) and 3Bar MAP sensor, PROJECT POWER’S latest waste gate hybrid turbo creation is chucking out SO MUCH air that even with dialling in maximum flow on the PP1’s… it’s under fuelling!

PROJECT POWER to the rescue again with a special build set of injectors using Wuzetem .260 Race nozzles. These are being installed next Tuesday along with a full compliment of PD150 head bolts. Maybe a belt a braces measure but this turbo is churning out 1.9 Bar!

How does it drive? Think Mercedes Brabus. Think Touareg V10 Tdi. OK obviously not a like for like comparison but the Torque on this thing now!! Motorway cruising is just effortless. No downshift only to go ‘a little bit faster’ just rest on the loud pedal and watch other cars shrink in the rear view ?.

Hills? I discovered tonight that it doesn’t just climb steadily. With four up, in the wet, in gear acceleration up long, steep inclines is just Off the charts. Think I’d better start saving for a Sachs organic clutch.

How does it all sound? Intoxicating!! Honestly. No its not an expensive VNT setup as many tuning companies have remarked during my build but the low rumble from the exhaust and the long turbo whistle accompanied by the pet OWL hoot Every time I lift off when I’m calmly driving through town cannot be produced with a VNT setup and I think it all adds to the experience of driving pleasure.
And the brutal roar that accompanies it all when I floor it is now Nothing like a van but everything that I could ask for as an entertaining drive.
Sounds best in tunnels! ?

Thanks Ron. I’ve got a feeling you’re going to be surprised with the numbers on this build. It’s never been about the numbers, I just wanted a strong, reliable van but I’m pretty certain this is going to be a milestone. I’ll post the dyno result on here as soon as its ready…..


The performance part of the build:

T4 2.5Tdi AJT Manual.

EGR clean out, block and delete (but retained the anti shudder valve).
Inlet manifold thoroughly cleaned out.
AXG airbox (larger diameter pipe) and MAF.
Reducer intake pipe.
PP GTRS?- Hybrid Turbo. Hope I get this bit right ... (bored out compressor housing, custom forged, milled, larger billet compressor wheel, re-profiled compressor cover and back plate, motorsport 360° phosphor bronze thrust bearing and uprated actuator - (( pet OWL)) ).
Rock fibre turbo heat shield.
Approx 30% larger top mount intercooler.
3bar MAP sensor.
PP 2.5” downpipe.
PP 2.5” cat-less exhaust system
PP1 injectors rebuilt with Wuzetem .260 Race nozzles.

I’ll probably heatwrap the down pipe, exhaust and coolant pipes that run near the intercooler but other than that I’m happy that this is now mechanically efficient and robustly built. Thanks to all that have been involved.

(I’ll take advice on the best rubber for this level of torque though. I’m currently running a full set of 3/4 tread 235/ 55/ 17 Goodyear Vector 4 season tyres and in damp conditions these can readily be lit up throughout 1st and 2nd unless I drive sedately).

  • I hope this is all of interest and use to other AJT owners... and Ron, you’ve become a good mate. Thanks for the top quality components and your help along the way. You are the very definition of Customer Service!
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Good job ! I always thought that large nozzles are to go for and going to the 0.260 is sensible- they can be turned down in the map. You were on good hands, Bobby's really a clever bloke and he is the last breed of blending mechanical knowledge with electronic programming- not many can do what it does...well ! Glad to know the k14 hybrid is delivering what it promises, unlike the pp0.5 or what they're called which are a waste of money in my opinion. Keep us posted with a dyno sheet...
 

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Like all injectors they should be sized to the power goal of the turbo. Having smaller injectors means that you end up keeping the injector open longer and missing the sweet spot of the ideal injection window. Larger nozzles can be pulled back and will keep smoke with egt's down. outside this window it will increase smoke and egt's. It's a fine line of being acceptable or not. Good atomisation of the fuel also helps and too larger nozzles does deliver fuel but it maynot be a fine spray, that's then down to increasing pump pressure. BSR knows his stuff and I'm due another session with him soon.
 

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Its not entirely true ! As you mentioned, large nozzles can keep the injection window very short due to ability to flow more in less time, what it does happen its pressure drops at some point hence the need for increased pressure at the pump. Small nozzles are made with emissions in mind, they can help passing stringent standards. I would spec the largest nozzles possible as it will leave enough scope for tuning- power is addictive and soon one gets bored with what it as and wants more ! Out o curiosity, how many times you've changed injector nozzles on your t4 ? Spend money once, same with turbos ! I have built so many hybrids that i know 90% of the time they're rubbish compared to a more modern stock turbo and don't get me started on billet compressor wheels ! A stock cast wheel will outperform a aftermarket billet alloy compressor wheel at every point on the efficiency map, designing a good wheel takes infinite amount of computer simulation, fluid mechanics and i would not trust any developing country with manufacturing it ! What these CNC producers do is copy models of working cast wheels from major manufacturers and they can make minute changes to their designs while you- the end user- do the beta testing for them...
I see the likes x-man, gotuned.pl and many more capitalizing/featuring billet wheel specs and promising the moon in the sky yet tuners have major headaches making these poor hybrids working half decent !
Also far east nozzles manufacturers are churning loads of garbage on the market: gibonta, wuzetem,firad etc...the only ones worth considering are Bosio which are Bosch copies, good but still copies ! Show me some manufacturer nozzles that works as well as 100k Bosch nozzles after no more than 10k miles...how many stories you hear of destroyed engines with cracked/melted pistons soon after poor sod had is pride and joy engine fully rebuilt ?!
Lets remember that our diesels are slow revving, de-tuned engines and they lasted this long because of simpler mechanical injection systems, in my opinion the manufacturers it the peaks of internal combustion engine developments in the 90's and everything else they churn out after that is just garbage with nice apple play or android auto interfaces and bi-led lights...
 

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adamss you really need to check yourself here.

Nozzle size depends on the application.

you say PP0.5 aren’t good - over 1000 of my satisfied customers would not agree. Please refrain from casting doubt over my products.

Bobby was actually quite surprised at how well they flow and he himself told me not to offer larger nozzles for this application as PP0.5 and PP1 were enough for what we wanted to achieve.

this project that Alan is pioneering on his van does call for larger nozzles due to a certain parameter determining lean running with a billet compressor wheel and a turbo built by one of the best guys in the Uk.

I have customers with 90k miles on our nozzles still running strong - quit the bullshit please. It’s really not cricket. We are a partnership of fuel injection specialists with over 45 years of combined experience.

our initial aim was affordable reliable accessible performance and we have achieved this for over 14 years.

now we are moving into a little more power and getting good results with our developments.

What does your T4 run ?
 

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Sorry Ron, it wasn't a point made at you, just my overall experience, I have started building hybrid turbos back in 2000 when chiptuning was in its glory and tuning boxes were all you could get bar a few remaps from Superchips or Bluefin ! I have built so many turbos i don't care to remember-back in the day getting AMG 3.0 tdi turbine or bmw gt2559v turbine with 65mm ford rs Cosworth compressor was the pinacle in tuning- back in the day Turbo Dynamics was still clipping gt20 turbines and were putting 56mm compressors and were claiming powers of 280Bhp on their MD line of turbos (50 Bhp short on optimistic dynos !)... I tried almost every nozzles there is from Firad, DSS Ultime, Bosio, Bosch and many more, none works as well as Bosch with Bosio following closely !

As for billet compressors, i have tried and used on my own cars 56, 60, 65, 69 and 71mm billet wheels from Sumalaya Turbo Company (almost everything you find on Alibaba or ebay it's their stuff !) either aluminium or titanium, none worked as well as the 65mm Garrett Cosworth cast wheel...all coupled with AMG style lighter twin journal seals turbine wheels...nearly all smoked on idle due to low boost to seat the seals so i started using only genuine garrett turbines...I now only modify stock turbos and rarely change compressor wheels, if i do its usually 6+6 blades- none of the 10-11 blades GTX style as they noisier and also flow less on our lousy diesel engines. Lighter and stronger billet wheels doesn't mean it will flow better, as I said designing good flowing turbine wheels geometry is a dark art !

My t4 is running well thank you, i have a bv50 turbo in the works as its almost plug and play on the stock manifolds, meanwhile its still running the old vw lt hybrid with ko4 compressor wheel and bosio race520 nozzles and i flash a de-tuned map every year when its due for MOT. I don't do much driving in it lately... I also have a water jet cut flange so i will one day build a custom tubular manifold to re-position a gtb2260vklr turbo so it fits better in the engine bay...busy workshop and family life + long commute takes away most of my energy and will to modify engines anymore !

Its a pity that the forum keeps changing passwords, i have tons of pictures from interesting projects i took part, from 750 Bhp 3.0 tdi track engines all the way to 2600 bhp drag queens ! I really do know what i am talking about, uk scene is well behind rest of europe with just a few like BSR, Darkside and MRC leading the way...

Once again sorry for creating confusion, i am in no shape or form criticizing your products as i wasn't able to try them on myself, just speaking from my experience in tuning world...i spent many nights and mucho dinerro's to grasp what i know and to offer free advice on low bandwidth forums that brings me no revenue unlike many out there...it even cost me a marriage my love of cars...so good luck folks, wherever you are !
 

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Discussion Starter #7 (Edited)
I can see people with a passion for this field coming at it from different angles.
I’m sure you both make valid points and from personal experience.

As an end user I am more than happy with the results so far and was quite surprised at Ron’s live response to the van’s running when I popped over for him to gain live data from his new turbo. I was expecting him to be quite run of the mill “Yeah this is normal from these upgrades” but he was genuinely ... frightened ??.
My van was the strongest I’ve known it yesterday and I couldn’t push it all the way because the motorway was literally like a river - my first and hopefully last experience of aqua planing.

For my pennies worth, it makes sense to me to commit to one tuning path and work with qualifiable information from the manufacturer as part of your decision making process on choosing the most durable components. This van, engine etc has been around a while, there are a choice of durable components to choose from by now.

Today it’s having PD150 headbolts installed, Wuzetem .260 nozzles which despite your experience with them? I’ve noted they have a cult following in America for German performance builds (even more so than Bosio which surprised me) so they can’t be quite That bad, and a new bottom pulley, water pump, cam belt etc.

Yep, the bottom pulley. Ladies and Gents, the bottom pulley should be fitted with a diamond washer..... on the inside edge. Not as a spare washer on the outside because we’re not really sure what it’s for... 30 seconds away from losing my whole engine today because of a tiny mistake be a mechanic 3 years back. I’ll post pictures in a bit.

Thankfully Daz at CEAutomotive identified the underlying issue quickly and is almost finished meticulously re-assembling it all. Really looking forward to driving it home. I’m told it will be as strong as an ox.

... And then the Remap ?
 

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Have just sent an ABL turbo to Ron for the Hybrid treatment, no doubt uprated pump and injectors will be needed as well.
 

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This is looking more like an advert for Rake's good's outside his trade page...
 

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"This is looking more like an advert for Rake's good's outside his trade page... "

Is that a problem if members are enthusiastic about him/his products?

Some time back (as I'm sure you will remember), I had some problems with a certain "mapper".....Ron/Rake was always there to help....unlike the other guy!!!
 

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"This is looking more like an advert for Rake's good's outside his trade page... "

Is that a problem if members are enthusiastic about him/his products?

Some time back (as I'm sure you will remember), I had some problems with a certain "mapper".....Ron/Rake was always there to help....unlike the other guy!!!
I know Ron is a good guy but I do hear and see what else goes on for good or bad. It just seems strange that a member with such a low post count has had more posts in a short time frame than all the time the op has been a member. Also it's on FB which I came across as well in the same format. It's my opinion what it looks like and you have a right to have yours. I see someone who has paided to have the complete job done rather than getting his hands dirty and then plugs who has done what. If the op is happy then that's fine but to me it still looks like an advert. Remember it's been posted in T4 chat and not in a build thread, I've done the same but it's in my build thread and it's been going for just on 5 years.
 

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You've helped me out many times on here Festa whether you know it or not but I've had my van 10 years have done most of it so don't often read build threads. Not everybody is capable of working on their vans and it was good to read this post which I would have missed in build threads.
 

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You know what, Truth be known Allan posted this initially on just T4’s and because of my history with this forum and this group of people I did ask him to post it in the forum.
I did assume that he would post it in the most appropriate forum and not in general T4 chat, but I guess Allan was just as excited as I am and posted it in what he thought was the most visible for him in a bid to help me. I can’t blame him for that but please don’t blame me for that.

i’m really passionate about what I do and when we have a customer such as Alan who is willing to go the lengths to reach his goals. His injectors were done at cost price his fuel pump was done at cost price And I have spent countless hours researching everything we needed to make this happen . no profit was made.
i’m genuinely excited about what we’ve got going on here and yes I want to sing it off the rooftops what’s wrong with that it’s a development that helps of the people achieve what they want from the vans.
i’m working with some really talented people to bring that to those who are interested in pursuing it. And Yes I’m like as excited as a little boy at Christmas because what we are doing appears to be working.
Was this post an advert ? not really I was just stoked.
This stuff is my everything.

@ adamss24 - sorry for sounding harsh, everyone has their opinion and experience
I respect that greatly. Peace.

time for bed
 

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Discussion Starter #18 (Edited)
Crumbs! Why so tetchy? Can’t see what the problem is here?

I posted on this forum because I thought there were other like minded people that were interested in successful build paths? Am I wrong?

Festa, Name your favourite race car driver. Who ever it is, maybe Grand Prix driver, do you think he pins the ‘cars’ success on ‘his’ mechanical skills?

Im not a mechanic. I have a rough idea and have enjoyed learning things about my van but because it’s not only my daily driver but also my bread and butter (it’s my work van), I can’t afford to get things wrong/ not have things running well or be spending time off work under the van.

I have, and will continue to use skilled professionals with a strong reputation for quality to supply their proven parts and skilled labour in ensuring that my van isn’t an old bag of bolts.

To those that have the time, circumstances and abilities to maintain more of their van on their own, I take my hat off to you.

My business runs on recommendation. 24 years in my trade. Because I appreciate how valuable referrals are to my efforts at my skills along with customer service I will always do what I can to back up other like minded tradesmen.

I’d like to think that many on here would speak positively about members builds and learn from the results? That’s what I came on here for. Was I wrong?

And as a closing comment, if you look on the Facebook T17 page you’ll notice James Hardacre was in CEAutomotive the day after my van was and mentioned Daz’s comments as he’d worked on it. No ghost writing going on here.
 

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Hmmmm.

You say this an AJT ?? The DMF becomes a real problem & starts to shake the van to bits above 160 bhp, yet I don't see any mention of this (did I miss it ?, I don't see the power figures either..), lots of gushing waffle but no real meat on the bones. I can fully understand Festa's comments - this does look like an advert, especially considering the amount of times you mention PP in capitals.

Incidently, like many others, I am technical and genuinely interested in the mods. Please publish the figures (minus any saccharine side salad).

HH
 

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Discussion Starter #20 (Edited)
O...k then.

Im running a single mass.
Next clutch will be Sachs organic at which point I’ll do the fifth gear conversion and uprate the strength of my 02B box. Apparently there’s a part I can order in from America? Need to look that up.

The gushing waffle is in anticipation of the result. When I get round to putting it on a rolling road after its final map I’ll post the figures.

PP is mentioned in capitals as it’s a name? Simple grammatics. Same as I’ve typed CEAutomotive a few times now. That didn’t get picked up on?

I’m already dead happy with how it drives. The figures are to help others see the progress and enable Ron to have the last word. Of course I’m sure there are those that will dispute that I’ve imported a Russian hamster raised solely on steroids to make the flywheel spin just that bit faster or that I’ve snuck into the rolling road place and planted a virus on their PC to give false readings. I guess it all makes life more interesting for some of us. I just like driving my van.
 
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