VR5-TURBO STAGE 4
Time for a new project tread for the new engine .
This is the 4th stage of the Bora/Jetta Mk4 turbo evolution. Updates this upgrade will get me in to high 10s low 11s with 1.7 60ft.
Turbo size have already proven to be a great upgrade after Team AVR 1,8T Golf Mk4 went 11,2/129mph with similar turbo .
So ... A list of modifications before i post the new pics under the headline This is just a feeler and soon i will post pics almost every week.
1:Race proven for 2 season tubular manifold will get 2 modifications . T25 bolt pattern with new pinbolts and coating instead of the old polished finish . Portes vs turbo inlet. EGT bung. With help from Josef Pilot custom pro welding
2:USRT 580cc injectors aka "600" @3bar
Will run em at 4 bar and use 50/50% alcohol for track days .
Street will still be on pump fuel
3:Spec stage 3/4 clutch
4:New final gear for the 02J because i was tired of putting 5th in @ 118mph and losing mph/sec
New high final drive for 130mph+ in 4th gear .
5:USRT Walbro 255lph inline fuel pump
6:Simens VDO catch tank to prevent car from going lean at hard acceleration and cornering
7:APR stage III intank fuel pump
8:USRT/Autotech light weight steel flywheel and ring gear
9:Modified turbo intake with integraded 3.5inch/90mm/86mm inner diam MAF
By Mattias Olsson custom pro welding .
10:Modified Plenum with new shape for even better flow for the last 3 cylinders. New unions Not polished ...i will do that later With help from Mattias Olsson custom pro welding .
11:Same Race proven semi cross flow 800hp intercooler with air scoop for more and better airflow through the core
12:USRT Lm-1 wide band lambda kit
13:New Garret GT BB style downpipe with "home made" flange
With help from Josef Pilot custom pro welding
3,5 inch cone to 4inch to fit the RS oulet from the exhaust flange without covering anything LIKE the ATP aftermarket 3 inch does. Free flow ! Exhaust wraped .
14:New Airfilter box with even smother inside and without plastic velocity stack from last years setup. OEM Paper filter . MAF mounted in semi-velocitystack maf housing . Smothed airbox for good flow .(box will support over 400hp with smothed innera and 4inch snorkel) Air box with 4.5 inch snorkel+stack
Huge K&N filter for track use .
Double filter area vs OEM .
But i will use OEM box and filter for street use .
Paper filter will support peak hp but will give me less reponse . But with much much cleaner air for street use .
RF-1004 Product Specifications
Product Style: Round Tapered Universal Air Filter
Base Outside Diameter: 5.75 in (146 mm)
Flange Angle: 10 degrees
Flange Inside Diameter: 3.5 in (89 mm)
Flange Length: 1.75 in (44 mm)
Flange Type: Angled
Height: 12.125 in (308 mm)
16:USRT/Tyrolsport adjustable FPR
17:New oil return assy/bracket
Oil return and turbo bracket
18:New home made gaskets
With help from Mattias and Josef
Home made gaskets
19orted and grinded K24 inlet T25 style flange Garret GtBB Turbine
-Wheel: 56.5mm w/ 84 trim
-Housing: 0.64 a/r
20:USRT Waste gate accutator 15psi
Custom adjustable WG
Notice the "perfect" bend for free flow .
Crappy silicone bend´s are a big no no for good flow .
21:ATP/Garret GT3071R-WG Dual BB, 64AR, 84 Trim Turbine
Fast spool is the key to fast quartermile times
450 spec HP BUT similar size AND with 22psi (waste gate semi open = good flow) Can make 450whp . Proven from last year making ~370whp from the small K24 0.41 A/R exhaust email@example.com Turbo With KKK24 flange
Notice the difference aginst T25 .
Custom ported gate that will open 90% for full flow at high rpm´s
22:Support by BILTEMA
Tools ,Airfilters,oil and new 17" wheels for 2006 .
( ©Photographer Håkan Ahldén)
23:Same home made catch can from last year.
24:Still same Pimpe´d Gauges from last year.
Oil pressure,boost pressure,Oil temp,EGT,And wide band lambda
26:I got a "top sectret project for the cyl head
8000RPM Cylinder head .
1:New natrium valves
2:New lifters from INA (latest version)
4:Autotech Sport tuned valve spring kit
OEM 230degr with 10.1mm lift 114!?!?lobe ctr
Let the rebuild of the new Super-vrthead begin.
These stiffer valve springs alone will extend the revving capabilities of your valvetrain to the 8000 rpm mark.
OR if i get some sort of sponsorship on this specific matter i would go for DSR 256degr 10,9lift 118 lobe ctr . DSR regrind is my only hope cause budget is low and a company here i Sweden has already made a set of FI 260s that didnt give me a single hp in 2004 .
I have e-mailed DSR about supporting me and im waiting on their answer
I will do the fine tuning of the valves/valve seat my self.
27:NEW bushings and modified stage III motor mounts.
1:Rock har bushings VS "soft" stage 3 uretane bushing . 2:ENGINE LOWERED 10mm to prevent turbo from hitting upper firewall
28: 70C Fan temp switch and 70c thermostat instad of the old 100c ones
Modified by foffa2002 at 10:39 AM 1-20-2006
Modified by foffa2002 at 6:15 AM 2-28-2006
Modified by foffa2002 at 1:10 PM 5-29-2006