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How to Turbo your 2.4d

Printed From: The Brick-yard
Category: T4 Section.
Forum Name: T4 Chat
Forum Description: Forum forT4 specific chat.
URL: http://www.brick-yard.co.uk/forum/forum_posts.asp?TID=45960
Printed Date: 29 Mar 24 at 13:52
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Topic: How to Turbo your 2.4d
Posted By: D&D
Subject: How to Turbo your 2.4d
Date Posted: 04 Nov 09 at 19:16

 I've searched nearly every site & finally found this, if you have any of the parts please pm me

http://www.angelfire.com/wv2/westfalia_california/Turbo_on_a_T4_2400D_aspirated_UK.htm - http://www.angelfire.com/wv2/westfalia_california/Turbo_on_a_T4_2400D_aspirated_UK.htm




Replies:
Posted By: NOELI0
Date Posted: 04 Nov 09 at 21:16
Nice find D&D, I'll wait till you do yours firstWink

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If you can't go fast go LOUD!!


Posted By: Rake
Date Posted: 04 Nov 09 at 22:35
Very nice little article indeed.


Posted By: onkobonko
Date Posted: 04 Nov 09 at 23:39
Hmmm, interesting, although it needs pump mods to take full advantage.  The 2.4 pump doesn't have a LDA so wouldn't be able to give any extra fuel on boost, I think Ive seen it done using the Volvo 2.4td (which is a VW engine) pump which is a bosch type and has an LDA (looks like an AAZ pump).

vwdiesel.net  is an excellent diesel tuning forum with lots of these king of mods

Side tracking slightly, Ive always thought that an AAZ pump when used with a 1.6TD boost pin, would be a good mod for a 1.9ABL to release extra power and make tuning easier, 90bhp would be easy, 100 or more with an intercooler...
I used to mess about with my old Passat and found a lot of extra power, posted this at the time if anyone intrested:
http://www.ukpassats.co.uk/phpbb/viewtopic.php?f=7&t=2770&hilit=johnboy


Posted By: D&D
Date Posted: 05 Nov 09 at 09:15
I'm in the process of collecting the parts, let you know how i get on..


Posted By: VW71Dave
Date Posted: 05 Nov 09 at 09:28
Originally posted by D&D D&D wrote:

I'm in the process of collecting the parts, let you know how i get on..
D&D,When you do it take some pics as i just picked up a 2.4 as my winter project.part numbers a must mate.Smile


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retards,r,us.


Posted By: ELVIS
Date Posted: 06 Nov 09 at 14:41

I *think* Seasider may have just bought a coach built T4 with a 2.4 that has been turboed........



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Www.justgiving.com/ELVIS-SUMMERS



Posted By: D&D
Date Posted: 06 Nov 09 at 16:02
Well i've got the turbo & manifolds, just need to get the oil lines & modded boost pipe housing for the inlet - can anyone help with these bits??


Posted By: D&D
Date Posted: 10 Nov 09 at 17:18
Here's where i'm at so far. Both 2.4 manifolds are off & i'm ready to hook up some oil lines, not sure where the return attaches to the block yet - any idea's - as its not clear on Etka?
INLET MANIFOLDS
 
The 2.4 manifold is a swine to remove because you cannot see the stud heads - use a mirror & lots of patience
 
 
EXHAUST MANIFOLDS
 
Take your time removing the old one, loads of heat & WD. I started with the bottom nuts then attacked the top, only two siezed - be prepared..
 
TURBO
 
OIL FEED
 
Cost so far is £80 for the manifolds & £190 for the turbo. I'll crack on again 2moro after i've kicked some arse on Modern Warfare 2
 
 


Posted By: Tee4
Date Posted: 10 Nov 09 at 18:29
Looks interesting


Posted By: D&D
Date Posted: 13 Nov 09 at 16:33
After some confusion I finally figured out where the turbo oil return is located, in the dipstick housing. Never seen a set up like this before & i'm sure it will be of use to other modders, saves you drilling holes in your sump (if your collecting your parts from a scrappie don't forget this part, its on back order from Vw & is thin on the ground)
 
 
I sold a bike recently so have had the luxury of buying all the oil pipework from the dealers - Oil feed & return pipes with their gubbins - dipstick housing - nuts,studs,washers - £167.00. Gaskets were from euro - £17.00
 
 
I've got to wait 10 days for the housing to come, I need to fit this first & connect to the filter housing before fitting the manifolds. Next job is to make a boost pipe attachement to fit on the inlet.. 


Posted By: D&D
Date Posted: 17 Nov 09 at 15:50
The new ACV dipstick tube arrived today so I fitted it along with the oil pipes. Fitting the tube is awkward due to its wider base, I got around this my removing the oil filter whick also helps when it comes to attaching the return pipe.
 
 
 
Both pipes fitted
 


Posted By: D&D
Date Posted: 20 Nov 09 at 19:44
Everything bolted in, just the boost hoses to connect
 
 
Fitted the hoses & alls well
 


Posted By: steve padda
Date Posted: 21 Nov 09 at 16:59
Hi
Good job bud waiting to see your feedback on the results  Big smile
 
steve
 
 


Posted By: D&D
Date Posted: 22 Nov 09 at 09:14

its transformed the van already & i'm only running 0.3bar, she pulls loads better. 50-80mph is where the big difference is noticed. i've fitted an L200 cooler but think I might have a boost leak somewhere, if it ever stops raining i'm going to up the fuel & take the boost to 0.5bar. Keep you posted



Posted By: Dirty1
Date Posted: 30 Nov 09 at 01:30
I have a 00 2.4, which model turbos fit?

The link states he uses a 96 2.5 turbo but I presme the later ones will fit too?

- just checking before I go an buy the wrong stuff!

Thanks!


Posted By: D&D
Date Posted: 30 Nov 09 at 04:55
Register here http://www.vagcat.com/ - http://www.vagcat.com/  & cross reference the catalogues, you'll get all the part numbers too


Posted By: DanT4Syncro
Date Posted: 02 Dec 09 at 13:38
Good work, so how many people have started or are going to start this?

I have it on a wish list for next year.  Though finding the time is going to be the hard part.

Cheers,

Dan


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Dan T


Posted By: Baxter
Date Posted: 02 Dec 09 at 13:44
Would the turbo fit with the standard 2.4D inlet manifold?
That inlet manofold looks like it would flow a lot better than the 2,5TDI item.
Are you going to intercool it?
Are you going to modify the injection pump top with a LDA so you get a bit more fuel on boost?


Posted By: D&D
Date Posted: 02 Dec 09 at 14:31
Hi Bax, i've fitted an L200 cooler & wound the max fuel screw in a wee bit, its now boosting 0.35 bar & running like a dream. Only problem so far is the idle is on the high side & I haven't figured out how to reduce it. Do you fancy having a play with it if I can get up to yours??


Posted By: Baxter
Date Posted: 02 Dec 09 at 14:42
Wind the throttle stop off.
If you give it more fuel, you do just that, because Diesels are throttle by fuel, then by giving it more fuel you have just raised the idle speed.
If you undo the cable, and undo the lock nut then screw the threaded rod back till you find an acceptable level.
If you drive it normally you probably won't notice the fuelling, but if you rag it , it will rev higher.


Posted By: D&D
Date Posted: 02 Dec 09 at 15:25

sorted, cheers for that. now i'm just resisting the urge to add more fuel & boost Nuke bang!!



Posted By: Baxter
Date Posted: 02 Dec 09 at 20:49

EGT's?



Posted By: Dirty1
Date Posted: 03 Dec 09 at 00:36
Ive looked up the VAG CAt site but I cant make sence of it, its showing a different turbo for the 96 on models and 2 types for the 00, on of which is yours!!

Im definetly going to do this, would it work well with a taller ratio 5 gear??


Posted By: D&D
Date Posted: 03 Dec 09 at 08:25
haven't a clue what the EGT is at! I'm adjusting fuel by eye(smoke test)  - it really needs setting up properly at a famous Independent Vw T3 & T4 specialists Wink


Posted By: D&D
Date Posted: 17 Dec 09 at 16:17
passed the MOT today so I upped the fuel by another 90 degree, well happy with it now!!

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Carthago 32.1 T4 LWB
BY Golden Nut Winner
Chug & Tug Team Member


Posted By: D&D
Date Posted: 06 Feb 10 at 20:34
update - after an oil leak started on the outer block i fitted an ACV steel HG, but after coolant pressure issues i've noticed it has less water holes than the ABB fibre HG Clap doh!
now fitted a steel triple notch steel AAB HG, problems solved but it really does need the 5th gear mod now


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Carthago 32.1 T4 LWB
BY Golden Nut Winner
Chug & Tug Team Member


Posted By: DanT4Syncro
Date Posted: 11 Feb 10 at 09:48
I'm keen on having a go at this but a little concerned about the possibility of over stressing my engine.  My 60 mile daily commute could do with a little more help on the hills but not at the sacrifice of my engines longer term health. D&D do you think your recent woes are due to the turbo addition?

Cheers,

Dan


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Dan T


Posted By: D&D
Date Posted: 12 Feb 10 at 05:35

I'd honestly say no. Most turbo engines run a steel gasket to accomodate the pressure & I was always going to swop the ABB fibre gasket following the conversion, the fibre gasket is pants. On removal it was clear that it was more than likely the original at 96k, these are renowned for blowing anyway. I know of several people running this conversion at 1.0bar with no issues, i'm only running 0.5bar which has transformed its performance. I also know of someone running two 3 notch triple steel HG's which reduces compression down to ACV spec & allows him to run a Volvo turbo at high pressure.



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Carthago 32.1 T4 LWB
BY Golden Nut Winner
Chug & Tug Team Member


Posted By: DanT4Syncro
Date Posted: 15 Feb 10 at 13:39
cheers for the reply.

I'm more and more tempted by this, my problem is going to be finding the time to source parts and do anything about it. To be honest I'd probably be better off coughing up for someone else to do it.


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Dan T


Posted By: Azzaaaaaaaa....
Date Posted: 17 Apr 10 at 10:17
Hi guys!! havent been on here for a while and just come across this turbo conversion and read the topic with great interest..... as the 2.4d are gutless when it comes to hills and the do need a kick up the arse....the only thing that worries me with said conversion is fueling at the higher end of the rev range under boost..friend of mine said about 2.4 turbo diesel toyota hi lux pump so might have to look into that ???

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Yea! What ever....!?


Posted By: raindriver
Date Posted: 30 Apr 10 at 02:38
Great work D&D!

Any chance you could post a full list of all the parts numbers, including the pipes and hoses? I'd also be grateful for more explanation of how you adjusted fueling, and what you're on about with the head gasket thing. I'm a diesel newbie, 'tho I've successfully stuffed a Jetta 1.8 into a T3 westy.

I have a coachbuilt with the 2.4D, and since I live in mountainous British Columbia, I've got a bit of an issue with hills...



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'93 T4 Karmann Gipsy
'92 GTI 8V
'04 Honda Element


Posted By: Terryturbo
Date Posted: 17 Nov 10 at 14:42
Great thread, i am defo looking to this to my 2.4.
 
where did you get the stainless head gasket from?
 
Great Job D&D


Posted By: D&D
Date Posted: 17 Nov 10 at 17:29
its not stainless, just plain ole steel. when you order a gasket you will be offered a choice of three, pick the steel one Wink

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Carthago 32.1 T4 LWB
BY Golden Nut Winner
Chug & Tug Team Member


Posted By: yorkstar
Date Posted: 07 Jan 11 at 10:31
hi if any one is thinking off turboin there 2.4d i have most of the parts availible ,
inlet manifold
outlet manifold
turbo
exhaust manifold
there is and oil feed pipe too but not sure if you`d use it
all came from a 2.5 tdi acv engine , was going to do convertion on mine but no time as van in constant use
ill add to for sale section too


Posted By: D&D
Date Posted: 29 Jan 11 at 19:20

great to meet you Matty, well chuffed with the parts. your syncro rocks too Thumbs Up


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Carthago 32.1 T4 LWB
BY Golden Nut Winner
Chug & Tug Team Member


Posted By: yorkstar
Date Posted: 29 Jan 11 at 22:45
pleasure to meet you too chap , glad your chuffed with the bits mate
would like to see the finished project one day ,
 also i might have to pick you brains again on the pump tuning
cheers
buddy


Posted By: Thumperstu
Date Posted: 21 Jun 11 at 19:58
Well im another convert to the 2.4D turbo group!!!!!
Got most of my bits off D&D and plenty of info....
In for a penny and all that and jumped in head first!!!
150K on my engine to start with but ran sweet, already has the steel HG on so plonked the turbo on, upped the boost 0.6 Bar, getting its first big run other than its daily commute over the weekend, Got a Saab FMIC to fit at some point.....Clap


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Stu :)


Posted By: dangerousdog
Date Posted: 22 Jun 11 at 23:06
Originally posted by D&D D&D wrote:

passed the MOT today so I upped the fuel by another 90 degree, well happy with it now!!
I just undone my 1.9 Iz abl hybrid one a full turn...Hell of a differance Wink

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soon be a new van !


Posted By: Brookster16v
Date Posted: 25 Nov 11 at 09:53

Nearly finished my 2.4D Turbo project im using the Volvo V70 K14 Turbo set up T:

only the exhaust to do now  that is getting welded up today, had to cut the V70 Downpipe down by 2" were the flange that bolts onto Turbo.

 


Should be able to fire it up tomorrow night

:ILU:



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Brookster16v


Posted By: D&D
Date Posted: 25 Nov 11 at 18:53

looking good Thumbs Up


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Carthago 32.1 T4 LWB
BY Golden Nut Winner
Chug & Tug Team Member


Posted By: Brookster16v
Date Posted: 27 Nov 11 at 09:22

Finally finished the install some minor items to sort but its ready to drive T: 

 
The Engine sounds really well with the Turbo fitted , runs alot quieter and a nice sounds from the Turbo
 
 The  K14 Turbo from the Volvo V70 TDI isn't a straight forward fit but i like a challenge but also the bigger Turbo has  alot for potential , but now i'm happy with the install just need to get an intercooler fitted.

Used the existing Air box and connected it with some 63mm duct.

Boost gauge and controller also fitted.



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Brookster16v


Posted By: Brookster16v
Date Posted: 27 Nov 11 at 15:55

Temporary Exhaust all sorted , budget side exit :D

just need to pull the old rear section off.

Time to get it on the road now and do some fine tuning T:

Turbo manifold flange close up shot

Air Filter fitted on Oil Breather

Better quality phot of the final install


Air Intake connection abit tight



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Brookster16v


Posted By: Brookster16v
Date Posted: 17 Dec 11 at 13:03

Time to fit the intercooler and increase the fuel , the fuel has been wound up


Had to remove the crimp off the screw, best way is to get a small flat screwdriver under the edge were it joins and force the screwdriver under with a hammer, that will split the crimp.

The a 13mm spanner to loosen the locking nut and then 6mm spanner to increase the fuel turning clockwise.

Gone for the mounting behind the grille , but now i've finished with i had fitted it at low level behind the bumper.

61mm cutter used as its all i had , 70mm would be better for the job.

Headlight needs trimming to clear the boost pipe.

Intercooler fitted and all boost pipes connected.

the grille needs alot of material removing to get it fitted, also the radiator needs setting back.

Been for a test drive and the van now pulls like a train , 0.5bar max at the moment and EGT's are below 500deg C. *<:-)>

I'm more than impressed with the conversion , i can now go camping or racing and not struggle up hills towing @ 40mph. :D

A few tweaks to finish off the Boost pipes, tried to make it look as Factory as possible may even paint the clamps black, and find some black bboost gauge pipe.
Run with the new set up and the EGT's are 570deg Max , and that's at max rpm & 0.6 bar so i'm comfortable with that. Just the exhaust that needs finishing may go for a full stainless side exit al also the adaptor onto the down needs making in 2" stainless. The down pipe is 2 1/2" so i could go for a full 21/2" system. T: 


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Brookster16v


Posted By: surfzone
Date Posted: 10 Mar 12 at 06:09
Hi all
its a long time since I have posted update on the van engine has been rebuild running and passed
MOT I have some photos of engine turbo
http://i235.photobucket.com/albums/ee158/keeble8181/Picture096.jpg" rel="nofollow - http://i235.photobucket.com/albums/ee158/keeble8181/Picture096.jpg
http://i235.photobucket.com/albums/ee158/keeble8181/Picture095.jpg" rel="nofollow - http://i235.photobucket.com/albums/ee158/keeble8181/Picture095.jpg
http://i235.photobucket.com/albums/ee158/keeble8181/Picture094.jpg" rel="nofollow - http://i235.photobucket.com/albums/ee158/keeble8181/Picture094.jpg
http://i235.photobucket.com/albums/ee158/keeble8181/Picture093.jpg" rel="nofollow - http://i235.photobucket.com/albums/ee158/keeble8181/Picture093.jpg
http://i235.photobucket.com/albums/ee158/keeble8181/Picture092.jpg" rel="nofollow - http://i235.photobucket.com/albums/ee158/keeble8181/Picture092.jpg
well along time coming, but this year I will be going to lux in her in September
next thing to do is interior multivan in that will be fun. Beer


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Posted By: Brookster16v
Date Posted: 28 Mar 13 at 13:36
photo's don't work Cry

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Brookster16v


Posted By: Brookster16v
Date Posted: 30 May 13 at 08:05

Transform your 2.4D in 8 hours with the Turbo Conversion T:



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Brookster16v



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