Audi 5 cyl Turbo Diesel

[colectb]

Hi, I have a running Audi 5000 turbo diesel, and two other 5kTD engines in need of a rebuild. I am new to tuning cars, as I usually just like to keep things stock.

 I was wondering what I can do do give them a bit more power; I eventually want to put one into a Porsche 924 and run it on a WVO kit, and It would be nice to have it be faster than stock.

Is the k24 sufficient? Would an intercooler increase power noticeably? Would I need to do anything to the injection pump?

Thanks in advance!

[rabbid79]

Those are cool engines.  Pretty much everything that can be done to the 1.6 TDs can be done to the 2.0 TD.  An intercooler would definately help, as would increased boost pressures.  I think most people on this board would agree that a 1.6 TD can be reliably taken to 125 HP using mostly stock components.  It can therefore be assumed that the 2.0 TD can be reliably taken to 150 HP.  As far as the K24 goes, what kind of power would you like to make?  I believe the Audi 5000 turbo gas engines used a K24, and they're good for 160 HP stock.  As for your pump, you may want to do the governor mod, and fiddle with the boost pin.  You may also want some larger nozzles.  I thought about putting a 2.0 TD in a 924 too, but it would be for Bonneville, not for fuel economy.

[colectb]

I just want to make as much power as possible without harming fuel economy at normal driving conditions, or even improving it.

That being said, anyone know where i can get a taller transmission, In the car that runs, the Turbo diesel is hooked to a NA 5 speed that's geared pretty damn low, harming economy.

I believe this is a k24 on this car is it not? The same used by the Audi gassers and the 931? Is there a better choice for a turbo as far as lag goes?

will an intercooler from a 944 turbo fit? I can get those for cheap.

I have no idea how to turn up boost nor do I know what is a safe level of boost. I'm pretty ignorant with these engines! Especially with timing; its pretty intimidating! At least I found a forum where some people may actually know something about these engines.

[rabbid79]

As far as I know, it is a K24.  The Audi gassers use K24s too, but they're water cooled as well, and have 4-bolt exhaust flanges, not 3 like the TDs.  I don't know about the turbo from a 931.  The 1979-80 had a larger one which was pretty laggy.  I understand it was taken from the 930.  The 1981-82 used a smaller turbo (higher compression ratio, and computerized ignition too) to improve lag.  The 931s also had an integraded pop-off valve in the compressor housing.

[colectb]

Actually the 5cyl turbo diesels have a 4 bolt exhaust flange too... So It is probably the same as the gassers then. Is there a good alternative to a k24 if I want something less laggy? How do you turn up boost and everything then? Whats too much?

[rabbid79]

I meant the 5 cyl. TDs have 3 bolts from the turbine housing to the down pipe.  The gassers have 4.  Read some of the 1.6 TD posts regarding boost pressure and wastegate bypass valves.  Most of this stuff will be the same.

[colectb]

Ok, I found a wealth of info. However, In my currently running engine, the previous owner (about 8,000 miles ago) rebuilt it with total seal gapless rings. I have seen on the internet that they are great for NA cars, but not for anything with power adders like turbos or nitrous. Should I stay away from doing anything besides an intercooler on this engine?

[TurboJ]

Light turboing shouldn't stress the engine much more than running it N/A.
It's a question of how you run it really.

Intercooling, a well flowing exhaust and an EGT gauge are your friends.
I wouldn't worry too much about those rings.

As for the intercooler - I would recommend the 951 intercooler. They're pretty good. Perhaps you can even use some of the boost piping?
But you'll need to modify your nose cone.. You know how the 924 Carrera GT and GTS had a hood scoop to feed a horizontal intercooler - that's because a 951-style intercooler wouldn't have any real airflow through it with a 924-style nose cone.  Maybe the 931 nose openings would help, but if it was me, I'd do a sort of a funnel that would feed from the engine radiator opening and onto the 951 I/C..

Bottom line - do it!!  I'll bet my Jetta on the fact that most forum members would like to see this 924 TD happen!!

[Pat Dolan]

I am one of those sitting on a 924/M471 and a 5000 TD, just waiting for the time to put the two together.  The first thing we need to know (my A car is stored one place, the P car 20 miles away) is if there is room for the fuel pump drive up against the firewall.

As are as gearing goes, this is a regular Audi 016 5 speed gearbox (unless you have one of the snail-case Porsche gearboxes from '81 or so), or if you have an early 4 speed car, it is an easy upgrade to 5 speed.  You want an entire gearbox (maybe a C1 platform NA diesel?? - where they 5 speeds??) I would expect.

Not a Bonneville car, but the ultimate low cost, ultra-efficient touring car.

[53 willys]

sure it's not a K26??? I pulled my K26 off a gasser Audi 5000...did some come with k24's and some with k26's???
maybe k24=diesel audi5000?
k26=gasser audi5000?

[rabbid79]

I'm almost 99% sure there won't be any clearance issues with the fuel pump and the firewall.  There's a 924 with a 5-cyl TDI engine on YouTube.  The biggest problem he had was getting the hood to close.  The engine was just too tall.  He had to cut a hole in the hood to get it to close.

An older 2.0 5-cyl TD would be a better fit since the engine is 16mm less-tall.  I'm almost certain that a volvo/VW 6-cylinder TD would fit in there too.  I think you'd have to get rid of the pop-up headlight mechanism, and trim the radiator fan shroud, but I think it would work.  Of course the problem with the engine sticking out of the hood gets that much worse by adding that 6th cylinder.  If I was ever to try a 924 TD Bonneville racer on a budget, that's the engine I would use.  A 928 transaxle too, since none of the 924/944/968 ratios wouldn't get me very far (~150MPH).

[colectb]

Yeah, as far as I know this would be a pretty direct swap except for motor mounts, since the 4cyl Audi block that Porsche used for the 924 actually had a 5 cyl. bolt pattern.  I think for normal driving, if you're not going for speed, the stock later 924 5 speed transmission would be pretty ideal, especially for efficiency, otherwise this is interesting, but I don't know if it applies for the 924, maybe just 944: http://www.lambolounge.com/Chassis/Transmission/5000/5000.asp

I really want to do this swap, but I'm still in school and i'm looking for the correct 924. I NEEEEED a pascha interior! I love that checkerboard!

I need to rebuild my other two engines in the mean time though, and get the most power possible out of one with mild modification.