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Author Topic: Holset swap info and flange adapter  (Read 4898 times)

February 15, 2017, 10:05:00 pm

RunninWild

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Holset swap info and flange adapter
« on: February 15, 2017, 10:05:00 pm »
I just ordered a HE211wg for my AAZ. I've looked around at what exactly needs to be done to make it work on our engines. The information has been scattered and some of it is hard to find so I figured I would collect it all into one spot for anyone looking to do this swap. I still have some questions and hopefully others can chime in and make this a good resource. I'll update this as others pitch in.

I'll start with the adapter plate for mounting the turbo onto our vw manifolds
These are pictures of the 2 different flanges we are trying to mate.
Vw exhaust flange diemsnions

T25 Exhaust flange dimensions:



You need roughly a 3 1/8" x 4 1/8" piece of steel I'm using 11/16" (16mm) thick as I found a piece at work, this needs to be roughly 3/16" or thicker then the head of the allen head bolts you use. Alcaid says the holset turbo flange is threaded to accept M8x1.25 bolts. The bottom 4 holes should be drilled to 9mm,  the middle 2 holes should be then counter sunk with a 14mm drill bit roughly 9mm or 10mm deep, the top 2 holes I would suggest drilling and tapping for the hardware of your choosing. I'm going with 10mm bolts on the top over 8mm because I think it will help center the flange in the manifold slightly as it originally used 10mm hardware.


Is what your adapter should look like when finished

The oil feed fitting required is M10x1.25 thread and should run a AN-4 hose with no restrictor. Alcaid says the stock oil feel is sufficient diameter however he suggests always replacing the lines when installing a new turbo. The oil feed banjo from the filter housing is M12x1.5.

The oil drain is a standard T3 oil drain flange with 2 M6x1.0 thread bolts. Holset recommends the drain be no less then 30 degrees to horizontal, and have a minimum internal diameter of 14mm, AN-10 or 5/8" would work perfect. The AAZ drain hole is threaded for M18x1.5 fitting.

The compressor inlet and outlets use a 2.25" V band fitting. A 2.25" silicone hose may or may not fit over the v band mount and work with a clamp.

He221w user manual http://myholsetturbo.com/manuals/HE221W.pdf The general information is the same between the he221w, he211w and he200wg as far as I know.

If anyone documented how they clocked the turbo feel free to post it. I'm installing this in my samurai so I have plenty of room and its not required.

The

Special thanks to Alcaid for supplying the information I havn't been able to figure out on my own. He's also the man to talk to when you are ready to order a turbo. Alcaid AKA Peter Lonning: [email protected]
« Last Edit: February 25, 2017, 08:18:21 pm by RunninWild »



Reply #1February 15, 2017, 10:30:04 pm

Jo3kr

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Re: Holset swap info and flange adapter
« Reply #1 on: February 15, 2017, 10:30:04 pm »
Oil feed M10 x 1.25


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Reply #2February 16, 2017, 12:23:17 am

vanbcguy

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Re: Holset swap info and flange adapter
« Reply #2 on: February 16, 2017, 12:23:17 am »
Made this a sticky!

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Bryn

1994 Jetta - AHU M-TDI - Jezebel Jetta
2004 Jetta Wagon - 1.8T - Blitzen

Reply #3February 16, 2017, 11:03:35 am

TylerDurden

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Re: Holset swap info and flange adapter
« Reply #3 on: February 16, 2017, 11:03:35 am »
Quote
Does anyone know the distance from the bottom bolt centers to the top bolt centers? I feel like I'm missing that dimension from the drawing.

If the same as 1.6, I'll go with 27mm off the horizontal centerline.



There seems to be plenty of room around the bolts... 10mm shanks, 12mm holes

Reply #4February 16, 2017, 01:13:34 pm

RunninWild

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Re: Holset swap info and flange adapter
« Reply #4 on: February 16, 2017, 01:13:34 pm »
Thanks for contributing! So bolt center to bolt center is roughly 54mm or is that outside to outside? Hard to tell on the the pic. Are you fairly certain 27mm from the center of the exhaust bore is accurate? I was planning on taking my turbo off to measure before I drill the holes but if you are confident I'll trust you.

I'll send alcaid a pm tonight and see if I can get a bit more info from him. I'll also attach his contact info to the thread so people can order from him if he wants me to.

Reply #5February 16, 2017, 01:59:26 pm

TylerDurden

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Re: Holset swap info and flange adapter
« Reply #5 on: February 16, 2017, 01:59:26 pm »
54mm is the center to center distance. I just divided in half.

I'll measure the whole thing and post the values to compare.

Reply #6February 16, 2017, 06:03:58 pm

TylerDurden

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Re: Holset swap info and flange adapter
« Reply #6 on: February 16, 2017, 06:03:58 pm »
This is the flange on the exhaust manifold I have handy.

 

Reply #7February 16, 2017, 09:11:46 pm

RunninWild

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Re: Holset swap info and flange adapter
« Reply #7 on: February 16, 2017, 09:11:46 pm »
I had a turbo gasket show up in the mail today so I will just use that. But your measurement is the same as I got. 2 1/8" bolt center to center

Reply #8February 16, 2017, 10:54:28 pm

4x4_Welder

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Re: Holset swap info and flange adapter
« Reply #8 on: February 16, 2017, 10:54:28 pm »
Good info, thanks.  I may explore a more ideally suited turbo for mine rather than just slapping on what I have.
Diesel tech and fabricator.

Reply #9February 20, 2017, 10:21:59 pm

Jo3kr

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Holset swap info and flange adapter
« Reply #9 on: February 20, 2017, 10:21:59 pm »
The compressor outlet and inlets you can get a silicone hose on no problem; however my turbo took a 3" silicone hose on the inlet. And the outlet I used the factory original 1.6TD silicone hose. All I did was use a hose clamp on the ring of the vband. Takes a few tries to get it to hold real well.

I got mine tuning in pretty well and here's a quick comparison from the old Garrett T4 to the Holset.

Garrett T4 EGTs WOT would peg it at 1600 easy (no intercooler factory) 10-13 psi boost.

Holset He221w EGTs WOT I have yet to exceed 1050F at 17 psi.

My fuel screw is the same it was when I had the Garrett on and it smoked like a train at WOT however the Holset uses every little bit it can get; right now I'm turning it in little by little I went from 10psi to 15psi with just a quarter turn.

The biggest problem I ran into is the downpipe; nearly impossible to find the correct vband for the flange your better off sliding a 3" vband over the original and welding it like I did. I have plenty of pics upon request.

And my oilfeed is simply 4an and the return is a homemade flange with a pipe welded onto it coming out about 3-4 inches with SS braided line to the pan.

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« Last Edit: February 20, 2017, 10:32:19 pm by Jo3kr »

Reply #10February 20, 2017, 11:39:37 pm

RunninWild

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Re: Holset swap info and flange adapter
« Reply #10 on: February 20, 2017, 11:39:37 pm »
are you running a intercooler with the holset? 1050f leaves quite a bit of room for more fuel! If that is without an intercooler I probably wont even bother with one. I'm hoping to run 20-25psi but might be hard to resist cranking it up further haha.
« Last Edit: February 20, 2017, 11:57:21 pm by RunninWild »

Reply #11February 21, 2017, 09:40:21 am

RabbitJockey

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Re: Holset swap info and flange adapter
« Reply #11 on: February 21, 2017, 09:40:21 am »
do you mean t3?
98 Pontiac Grand Prix GT:stock daily
 81 Jetta: in progress 1.6td, ported head, holset turbo.
81 Rabbit:AAZ, hybrid T3 turbo, Giles pump, lightened fw, and yellow clutchnet clutch.

Reply #12March 15, 2017, 11:20:22 pm

Gizmoman

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Re: Holset swap info and flange adapter
« Reply #12 on: March 15, 2017, 11:20:22 pm »
Nice to know I contributed something. The Holset is a great turbo for sure.
Jim W - 82 Vanagon Westy - AAZ 1.9, Mild head port, Cummins Holset HE200WE turbo, Frozen Boost WAIC, 10" Charge-pipe intake, Ball bearing IM shaft, Giles Pump, 215/70R16, AAP 5 speed Trans. 22 lbs max boost

Reply #13March 27, 2017, 06:15:14 pm

Gizmoman

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Re: Holset swap info and flange adapter
« Reply #13 on: March 27, 2017, 06:15:14 pm »
Here's the drawing of the adapter shown in the photo above
Jim W - 82 Vanagon Westy - AAZ 1.9, Mild head port, Cummins Holset HE200WE turbo, Frozen Boost WAIC, 10" Charge-pipe intake, Ball bearing IM shaft, Giles Pump, 215/70R16, AAP 5 speed Trans. 22 lbs max boost

 

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