Sharkie's TSI Amarok Build

[Sharkie]

Bit of an update ....

The AWD conversion actually looks pretty straightforward. All the mounts etc, bolt holes etc are all there on the TSI chassis. Once I finish work on the GTI Polo (which is nearing the end now) the conversion will start.

Once the AWD conversion is in and running the next power stage build will commence. Thanks to a donation of a MK6 GTI exhaust camshaft from HP, i ordered the KO4 kit from HPA (thanks Spring sale) 2.0T K04 Turbo Upgrade Longitudianal
– HPA Motorsports, so a MK6 GTI K04 Stg 3 tune will be able to be loaded netting 250+kw and well over 500NM of torque.

[Sharkie]

I thought I read somewhere that the zf gearbox was only good for 450nm torque and/or 200kw? Not totally sure on the numbers but that’s why the v6 was auto not manual.(apart from a limited number of detuned cores)


Sent from me [emoji2957]

Stock rating on the 6spd manual for the BiTDI and TSI is 450NM. That does not mean it cannot handle more ..... Tuned BiTDIs typically put 550+NM through the boxes with little complaint.

My Golf R's 6spd manual is rated at 350NM and has handled more than 500NM for over 3 years quite happily so far.

For what it's worth this conversion will include a visit to a gearbox specialist as I want the internals redone to lengthen the ratios on 1st, 2nd and 3rd and to fit more robust synchros and possibly stronger gears. And finally will be followed up by an aftermarket clutch that can handle up to 750NM.

[lloydus67]

I thought I read somewhere that the zf gearbox was only good for 450nm torque and/or 200kw? Not totally sure on the numbers but that’s why the v6 was auto not manual.(apart from a limited number of detuned cores)


Sent from me [emoji2957]

[TSOTSI]

Cant wait to see this progress build going to epic Sharkie...

[Sharkie]

So as part of the path to getting a full Stg 3 motor build, we identified that traction will be a problem due to the fact the TSIs only ever came in RWD. With Big Red developing a 3rd gear synchro issue of late, and with us getting more adventurous with our builds, this arrived this week ....

Manual TDI400


Can a conversion be done? All research points that way, so we will found out over the next few months.

[EZZA]

This thing is going to be a beast once you're done!!

[The_Hawk]

I love watching your builds

[TSOTSI]

going to be and epic build and fun drive I would say. busy doing a decarbon on mine will get to mods as well

[Sharkie]

In planning stages on taking Big Red to a K04 upgrade in the not too distant future. I have mapped every engine part to the equivalent engine part in the MK6 GTI (engine code CCTA) and there are only 3 material differences ... exhaust cam, turbo and ECU (and the Amarok intake manifold does not have the runner flaps it seems)

Use these as a starting point and navigate up to the correct engine section.

Amarok TSI
intake system; vacuum system Amarok (AMA) 2013 year Volkswagen EUROPA 133030

GTI engine - look for CCTA
intake system; vacuum system Golf/Variant/4Motion (GOLF) 2012 year Volkswagen EUROPA 133030

Found the K04 (2.0T K04 Turbo Upgrade Longitudinal
– HPA Motorsports) needed and the intake (2.0T FSI/TSI Intake Manifold V2
– HPA Motorsports) upgrade to do the swap from HPA Motorsports. Then "only" need to load the appropriate K04 tune (HPA Stage 3 K04 Hybrid Tune
– HPA Motorsports) to the Amarok ECU. Sounds easy but I am still researching whether this would be possible ...

~270kw/500NM is the expected result I believe

Also researching what would be needed to "build" the motor for stage 3 and since the Amarok and CCTA engines uses the exact same pistons, rods and rings, any aftermarket forged setup suitable for the CCTA will work

[Dinogzav]

Hey mate, wondering if you've done any research into HD clutch kits. Mines been tuned for about 20,000km now and the clutch is slowly letting go. Mechanic says go standard Sach's or Exedy kit but i'm looking into HD kits like Xtreme Outback dual mass to help hold the extra power. Thoughts?!

Maybe also talk to NPC. They make some nice clutches. I had one in my 800Nm TD42 Patrol.

[EZZA]

Hey mate, wondering if you've done any research into HD clutch kits. Mines been tuned for about 20,000km now and the clutch is slowly letting go. Mechanic says go standard Sach's or Exedy kit but i'm looking into HD kits like Xtreme Outback dual mass to help hold the extra power. Thoughts?!

[kentwbird]

Its actually been tuned since 2015 (well before the V6s came out) Launching a manual tuned petrol Amarok is much more violent than any of the V6s ..... That auto box in the V6 takes most of the violence out of it .... I know, have done both

there are manual v6's now too tho...love the tsi tho

[EZZA]

Peak boost of ~22PSI on the TSI. Simply can't do a launch video holding a phone as its a bit violent .... ~6.5s 0-100 in an Amarok is a wild ride

Nice!! I like the sound of the exhaust too. Gotta love the old 'Puffing Billy' train whistle as my kids call it haha!

I'll second the tuned TSI launch, reminds me of my old 13B RX3 bridgeport but alot less wheelspin

Blue RX3 Stampede at Easternats 2009 - YouTube

[TSOTSI]

OOO LALA, That looks like fun, I hope neck braces are std in your TSI.

[Sharkie]

welcome to tuned v6 life!

Its actually been tuned since 2015 (well before the V6s came out) Launching a manual tuned petrol Amarok is much more violent than any of the V6s ..... That auto box in the V6 takes most of the violence out of it .... I know, have done both