My 250+HP CRD build

CATCRD · **Posted:** Wed Jun 11, 2014 5:59 pm

Can't wait to see it tuned. Some in-cab footage while driving would be cool.

diesel_guy86 · **Posted:** Wed Jun 11, 2014 9:13 pm

Wish I would have taken a video of it now, it runs and sounds a lot better with all the stuff on it. I'll try to get as much video tomorrow as I can. Hoping and praying everything stays together and no leaks or whatever show up.

diesel_guy86 · **Posted:** Thu Jun 12, 2014 12:53 am

It drives! No leaks of any kind, just a very loud and annoying exhaust. I didn't hammer on it, but I got boost up to 10psi and egt was at 1,000°F. Hopefully that'll be evened out after tomorrow. For now its a shower and 4 1/2 hours of sleep and then GDE.

CB Eng · **Posted:** Thu Jun 12, 2014 9:54 am

Good work. Looking forward to seeing after you get it tuned.
I bet it's pretty loud without any exhaust and opening right under the Jeep.

diesel_guy86 · **Posted:** Thu Jun 12, 2014 5:11 pm

Just got er unloaded from the road trip from GDE. Kieth, thank you again for your time and patience this morning.
Things started off rocky when the ecu locked up and wouldn't let the jeep start. Then we found a coolant leak and a bolt I forgot to tighten. Got tune loaded in, bolt tightened up, added some water, and then found the map sensor failed. Luckily he had another one, swapped it out and off we went. First hit boost was low ~10lbs, and it smoked like a pullin truck. Adjusted the wastegate actuator and same thing, only on the second punch, we found a clamp I forgot. Argh! Got the hose put back on, clamp on good, and then pulled the hose going to the wastegate and plugged it. Went and lined up on the back straight away and punched it.
Started moving along, only this time when the engine hit 3,000 rpms, the boost shot up to 26psi and we were gone! I let off at first in fear of shooting over 30psi, but the other runs showed it holding steady at 26. Smoke was gone too except for the initial hit. At this point it was raining cats and dogs so we called it for the day. I have several minor things to get fixed before she's back to being a daily driver. The jeep sounds like someone stuck a jet engine under the hood, the sound is very unique. Kieth estimated I was putting out about 215hp, I got home and ran it on dry pavement with the torque pro app and got this:

Bottom left it says max HP 252, to the wheels! Also it beats the turbo kits 0-60mph time, barely. If it would spool just 300 rpm sooner itd roast the rear tires and would be in the 7.5 second range. Here's a quick clip of a 0-60 run. You can't hear the turbo very well, but watch the tach when it gets to 3,000 rpms.
http://youtu.be/POj68oDjAAc

flman · **Posted:** Thu Jun 12, 2014 6:05 pm

That thing kicks Arse, I would love to see the 3.7 gasser do that? Only in a dream.

tigafila · **Posted:** Thu Jun 12, 2014 6:16 pm

Real nice build.

jws84_02 · **Posted:** Thu Jun 12, 2014 9:40 pm

Good results. Recruit someone to take a video of you messing around in it.

diesel_guy86 · **Posted:** Thu Jun 12, 2014 9:51 pm

Good idea, I'll do that once I get the exhaust done. The down pipe dumps out right by the oil filter and transmission lines, heating that area and coating it in soot. Plus it sounds like poo with all the sound bouncing around off the body and road and what not.
I'm playing with the idea of swapping out the 2860 for the the 2560 for better low end response, shouldn't sacrifice the top end any. I have to take it off to fix the leak on the water pump anyways.

thermorex · **Posted:** Thu Jun 12, 2014 10:43 pm

I've been waiting for this video since you created the thread. Beautiful noise, I like it!

Next step is to put an Audi r10 tdi engine in it, lol.

diesel_guy86 · **Posted:** Sun Jun 15, 2014 12:03 am

This 4 in a row engine is packed in tight enough! Is that the same engine that is in the older vw touregs? I ALMOST traded the crd in on one, but lack of a close dealer and rumours of VERY expensive repairs (as in pulling engine out to change alternators) I decided to keep my crd. Short while later it decided to eat itself

Anyways, ordered the gen 2 fuel head, yes I have a lift pump and it shouldn't matter, but its a piece of mind. Also ordered the .64 "ni-resist" ar housing. Current one is .83. The 64 should lower spool up a few hundred rpm, as well as up the boost on the higher end. I have a 30psi gauge, but the needle seems to stop dead at 26psi. You would think as flow increased so would the boost. I'm wondering if the gauge is mis-calibrated and its actually 30psi+. I can't remember what kieth was seeing on his display. Should be done this coming weekend, I'll get more video both inside and out.

thermorex · **Posted:** Sun Jun 15, 2014 2:48 am

I think all touaregs tdi came with v6 and v10, and I doubt vw would use a vm engine when they are one of the best diesel engine makers in the world. But taking the engine out to replace an alternator... That's insane...

diesel_guy86 · **Posted:** Fri Jun 20, 2014 11:40 pm

Tore the gt2860r turbo off tonight so I could take it to the turbo builder tomorrow to get a billet wheel installed. I was pretty upset when I popped the exhaust housing off and found the turbine wheel tips melted off :furious:

. was supposed to be a turbo used for mockup, but evidently the previous owner used it for a little more than "mockup". So I grabbed the 2560 I had gotten from notpicky and popped its exhaust housing off and found it too was damaged! So gonna call the builder and see if he has any new parts, if not I'll have to order a new center rotating assembly.
This started because I wasn't happy with the boost/ egt I was getting. Egt seemed high while boost was low, and also spun up slow. So I figured if I could spin a bigger compressor wheel at the same speed, I should get more pressure, which would cool the egts down, and the billet wheels lighter weight would let it spool up quicker.
Guess we'll see in the morning.

thermorex · **Posted:** Sat Jun 21, 2014 12:16 am

Oh boy... So this will cost you some extra hundreds... Btw, did you make your own turbo flange to mount it on the exhaust manifold or you got the turbo with the flange? I'm thinking to get a little better turbo for the Mercedes om617, some newer version than the t3 that the car has, and I am interested on who makes the flange adapter. Also, does your turbo have a wastegate? If yes, is it easy to adjust without taking apart a bunch of other accessories?

diesel_guy86 · **Posted:** Sat Jun 21, 2014 12:26 am

A guy on here (notpicky) actually designed them and had them made. Its a nice setup and the best part is your manifold doesn't get modified, you can take it back to stock if you wanted.
Yes, it does have a wastegate. I made my own wastegate controller, its really simple and costs like $10. I thought about posting pics as I built it but I was in a time crunch and every second counted. Its just an adjustable pressure relief valve. The more you turn the screw in, the more spring pressure there is and the more boost it takes to over ride it. Google diy boost controller and there's tons of pages of how to do it. I took mine out because I didn't have a heavy enough spring.

thermorex · **Posted:** Sat Jun 21, 2014 10:53 pm

Cool, thanks a lot! I can send you a wastegate if you wanna see if it can work but I think you can go to max 20 psi with it, if it can be set that high... I have an old one from the t3 I replaced on the Mercedes om617. Stock wastegate opens right after 12psi, but I remember people on forum saying you can set it up for 20 (which will kill that engine on the mercedes) but don't quote me on that. You take out a cap from the wastegate and there is a lock nut that you undo and about 3 turns give 2 psi boost. Let me know if you want to try it. I didn't look to see how long the thread is or if it can be replaced... I wonder if there are not universals for sale.

diesel_guy86 · **Posted:** Sun Jun 22, 2014 12:10 am

Never seen one of those. The controller I made goes in the line going from the compressor housing to the wastegate. A whole lot faster to adjust.

thermorex · **Posted:** Mon Jun 23, 2014 10:25 am

That wastegate has a hose from the compressor and it releases in the exhaust side, I may have not been very clear in my description, pretty much is the standard operation for any wastegate I have seen, but it's not easy to adjust due to the way it's positioned and the tiny space. I'm pretty sure yours is way easier to tweak.

MassiveNine · **Joined:** Tue Sep 25, 2012 10:24 pm **Posts:** 18

Pretty awesome build. Mind telling how much you have invested into the swap thus far?

diesel_guy86 · **Posted:** Wed Jun 25, 2014 1:16 pm

Kinda hard to say, I bought a turbo before all this for $400, got the kit that consisted of a couple adapters, an exhaust housing and another turbo for $600, then when I found both turbos were damaged I had to plop down another $900, plus the vband adapter and downpipe for $200. So $2300. If you were to buy a new turbo and do it right the first time you'd probably have $1,000 in the whole thing. The same price as the factory turbo, with the piece of mind you have a turbo that will last as long as your engine does.

My 250+HP CRD build

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