850 tdi upgrade project

martin_r_smith · Jan 16th, 2015, 18:15

Thought I would put a few build pics up as the engine work is just about finished now. My goal is to reach 230-240 bhp and somewhere in the region of 360 ft/lb of torque. I'm still putting a few miles on it before I go all out but my ar5e dyno says it's not far off!

Anyway the build:

All the front end removed ready for the big intercooler. It seems there is even less space than a T5 to wedge a 3" one in but it is possible minus air con.

Manifolds removed to make way for the 16t.

After some swear words the 16t fits a treat. A custom bracket for the actuator had to be made due to the turbo being rotated.

The oil feed and return lines needed modifying and I was quite surprised how much smaller the diameter of the c70 return line is compared to the tdi one. Going to see how I get on without water lines to start with, I have read up on it and asked several experts their opinion and they think it will be fine as a diesel runs a lot cooler.

I will get more pics up over the weekend.

martin_r_smith · Jan 16th, 2015, 18:46

Found some more pics..

The modified manifold ready to take a td04 16t, next to old k14 housing.

It is surprising how restrictive the standard one is really. With the poorly designed wastegate setup of the standard k14 too its not surprising 200+bhp isn't really possible, believe me I tried!! Exhaust manifold pressure is huge due to the restrictions, so much so the exhaust valves cannot seat properly due to the back pressure.

This is the manifold with the 16t on.

I have used the old egr port to place a fitting for monitoring emp.

brickman · Jan 16th, 2015, 20:00

Been waiting for this for a while, looks like she'll be a monster!

Never looked down into the exhaust manifold but can see why its not so ideal.

martin_r_smith · Jan 16th, 2015, 20:08

She feels a monster lol. Once I've done some miles I will get the final mapping done and the engine work should be finished.........for now!

I've been driving an 850 T5 saloon whilst mine has been off the road and I can honestly say my diesel has a lot more pull. It may not be as fast (ie top speed) but is certainly quicker on the road.

klunk · Jan 17th, 2015, 11:40

Update at last! Ace. I cannot believe how ridiculously restrictive the original manifold is? In your opinion is it possible to open it up a bit quite easily or is it on the limits?

martin_r_smith · Jan 17th, 2015, 14:04

I've opened mine up a bit but you definitely wouldn't get any gains if your sticking with the standard turbo. A bigger turbo is a must to get any descent or worthy gains.

martin_r_smith · Jan 17th, 2015, 18:04

The big intercooler was a tight fit but managed to go in with minimal trimming to the front panel. I know people will wonder why I haven't relocated the horns or trimmed the centre piece out for 'increased' air flow, but i wanted a completely standard look so they are staying where they are.

Nice shot of the turbo all plumbed in. The copper coil is to disapate heat from the exhaust gas before it gets to the guage to monitor emp.

General overview of the engine bay now it's all back together. I'm going to paint the shiny pipe black as it's not 'factory' enough for me.

The pipe work from the turbo to intercooler had to be changed due to the outlet on the intercooler coming out of the side not the front/back where the original one is. The hardest part was replacing the stupid twisty factory bottom pipe, what a crap design that is! Anyway all 2.5" now and nicely routed. Couldn't get great pics of it but you'll get the idea.

Can you spot what's missing here??

Give you a clue it weighs about 15kgs and is the size of a suit case lol.

brickman · Jan 17th, 2015, 18:15

Straight pipe, or have you moved silencers to aft of rear axle ah la AWD?

Always fancied fitting the twin pipe setup from an R, as Im a sucker for a wagon with twin pipes, petrol or diesel, just looks right.

Also how fecking clean is your sump!

martin_r_smith · Jan 17th, 2015, 18:22

Yeah my engine seems to defy the rule that these things leak no matter what lol.

I have a small (302mm long) resonator just behind the rear axle. I had my tail pipe chopped off and connected to this to keep it looking original.

brickman · Jan 17th, 2015, 20:10

This is turning into a weapon of mass coal production

Jan 16th, 2015, 18:15	#1
martin_r_smith Premier Member Last Online: May 10th, 2022 21:01 Join Date: May 2009 Location: Wiltshire	850 tdi upgrade project Thought I would put a few build pics up as the engine work is just about finished now. My goal is to reach 230-240 bhp and somewhere in the region of 360 ft/lb of torque. I'm still putting a few miles on it before I go all out but my ar5e dyno says it's not far off! Anyway the build: All the front end removed ready for the big intercooler. It seems there is even less space than a T5 to wedge a 3" one in but it is possible minus air con. Manifolds removed to make way for the 16t. After some swear words the 16t fits a treat. A custom bracket for the actuator had to be made due to the turbo being rotated. The oil feed and return lines needed modifying and I was quite surprised how much smaller the diameter of the c70 return line is compared to the tdi one. Going to see how I get on without water lines to start with, I have read up on it and asked several experts their opinion and they think it will be fine as a diesel runs a lot cooler. I will get more pics up over the weekend. __________________ 1983 244 Last edited by martin_r_smith; Jan 16th, 2015 at 18:30.

Jan 16th, 2015, 18:46	#2
martin_r_smith Premier Member Last Online: May 10th, 2022 21:01 Join Date: May 2009 Location: Wiltshire	Found some more pics.. The modified manifold ready to take a td04 16t, next to old k14 housing. It is surprising how restrictive the standard one is really. With the poorly designed wastegate setup of the standard k14 too its not surprising 200+bhp isn't really possible, believe me I tried!! Exhaust manifold pressure is huge due to the restrictions, so much so the exhaust valves cannot seat properly due to the back pressure. This is the manifold with the 16t on. I have used the old egr port to place a fitting for monitoring emp. __________________ 1983 244

Jan 16th, 2015, 20:00	#3
brickman Premier Member Last Online: Nov 14th, 2023 10:40 Join Date: Jul 2013 Location: Glasgow	Been waiting for this for a while, looks like she'll be a monster! Never looked down into the exhaust manifold but can see why its not so ideal. __________________

Jan 16th, 2015, 20:08	#4
martin_r_smith Premier Member Last Online: May 10th, 2022 21:01 Join Date: May 2009 Location: Wiltshire	She feels a monster lol. Once I've done some miles I will get the final mapping done and the engine work should be finished.........for now! I've been driving an 850 T5 saloon whilst mine has been off the road and I can honestly say my diesel has a lot more pull. It may not be as fast (ie top speed) but is certainly quicker on the road. __________________ 1983 244

Jan 17th, 2015, 11:40	#5
klunk Member Last Online: May 31st, 2023 20:03 Join Date: Jul 2013 Location: Barnstaple	Update at last! Ace. I cannot believe how ridiculously restrictive the original manifold is? In your opinion is it possible to open it up a bit quite easily or is it on the limits? __________________ 1995 855 T5 Manual 1996 855 TDI Manual Last edited by klunk; Jan 17th, 2015 at 11:45.

Jan 17th, 2015, 14:04	#6
martin_r_smith Premier Member Last Online: May 10th, 2022 21:01 Join Date: May 2009 Location: Wiltshire	I've opened mine up a bit but you definitely wouldn't get any gains if your sticking with the standard turbo. A bigger turbo is a must to get any descent or worthy gains. __________________ 1983 244

Jan 17th, 2015, 18:04	#7
martin_r_smith Premier Member Last Online: May 10th, 2022 21:01 Join Date: May 2009 Location: Wiltshire	The big intercooler was a tight fit but managed to go in with minimal trimming to the front panel. I know people will wonder why I haven't relocated the horns or trimmed the centre piece out for 'increased' air flow, but i wanted a completely standard look so they are staying where they are. Nice shot of the turbo all plumbed in. The copper coil is to disapate heat from the exhaust gas before it gets to the guage to monitor emp. General overview of the engine bay now it's all back together. I'm going to paint the shiny pipe black as it's not 'factory' enough for me. The pipe work from the turbo to intercooler had to be changed due to the outlet on the intercooler coming out of the side not the front/back where the original one is. The hardest part was replacing the stupid twisty factory bottom pipe, what a crap design that is! Anyway all 2.5" now and nicely routed. Couldn't get great pics of it but you'll get the idea. Can you spot what's missing here?? Give you a clue it weighs about 15kgs and is the size of a suit case lol. __________________ 1983 244 Last edited by martin_r_smith; Jan 17th, 2015 at 18:06.

Jan 17th, 2015, 18:15	#8
brickman Premier Member Last Online: Nov 14th, 2023 10:40 Join Date: Jul 2013 Location: Glasgow	Straight pipe, or have you moved silencers to aft of rear axle ah la AWD? Always fancied fitting the twin pipe setup from an R, as Im a sucker for a wagon with twin pipes, petrol or diesel, just looks right. Also how fecking clean is your sump! __________________

Jan 17th, 2015, 18:22	#9
martin_r_smith Premier Member Last Online: May 10th, 2022 21:01 Join Date: May 2009 Location: Wiltshire	Yeah my engine seems to defy the rule that these things leak no matter what lol. I have a small (302mm long) resonator just behind the rear axle. I had my tail pipe chopped off and connected to this to keep it looking original. __________________ 1983 244

Jan 17th, 2015, 20:10	#10
brickman Premier Member Last Online: Nov 14th, 2023 10:40 Join Date: Jul 2013 Location: Glasgow	This is turning into a weapon of mass coal production __________________

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