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.
http://i1164.photobucket.com/albums/...h/DSC_0490.jpg

Manifolds removed to make way for the 16t.http://i1164.photobucket.com/albums/...h/DSC_0495.jpg

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.http://i1164.photobucket.com/albums/...h/DSC_0491.jpg

http://i1164.photobucket.com/albums/...h/DSC_0492.jpg

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.

Found some more pics..

The modified manifold ready to take a td04 16t, next to old k14 housing.http://i1164.photobucket.com/albums/...h/DSC_0438.jpg

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.http://i1164.photobucket.com/albums/...h/DSC_0437.jpg

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

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.

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.

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?

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.

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.
http://i1164.photobucket.com/albums/...s/DSC_0502.jpg

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.http://i1164.photobucket.com/albums/...s/DSC_0508.jpg

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.
http://i1164.photobucket.com/albums/...s/DSC_0503.jpg

http://i1164.photobucket.com/albums/...s/DSC_0504.jpg

http://i1164.photobucket.com/albums/...s/DSC_0507.jpg

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.

http://i1164.photobucket.com/albums/...h/DSC_0500.jpg

http://i1164.photobucket.com/albums/...h/DSC_0501.jpg

Can you spot what's missing here?? http://i1164.photobucket.com/albums/...h/DSC_0509.jpg

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

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!

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.

This is turning into a weapon of mass coal production :car-smiley-004: