TTE420 begins as a brand new standard BorgWarner K04-064 turbocharger that is dismantled and then set about upgrading and optimizing to create the ultimate K04 frame hybrid for the EA888.1. TTE420 Turbocharger is great power stage for the 2.0 TSI range of vehicles while retaining like OE fitment.
Engineered & Enhanced
The formula to making a TTE420 starts with a much larger 2871X TTE billet compressor wheel, chosen because is highly efficient, new generation type with very thin blades, creating extremely high flow for comparative size, giving a compressor map that's very wide. The Re-profiled compressor cover is machined to an optimized tolerance to ensure maximum compressor efficiency. TTE blanks off the original PCV port as not required and fit their TTE smooth flow optimized billet blanking plate cover. The intake pipe is CNC ported and hand finished with the TTE smooth flow cover fitted to give a smooth tract and transition for the incoming air for the ultimate flow.
TTE also fits their Billet CNC TTE Boost adapter & silencer delete. Removing any restriction so improving the flow and enhancing the sound. TTE CNC mills the compressor cover to accept their CNC Billet TTE Recirculation Valve Adapter to fit an Original VAG Recirculation valve to give OE like fitment with trouble free operation.
A key part to driving the large 2871X compressor and in turn making this unit produce the huge power advantage over stock, is machining and fitting a far larger BorgWarner K16 curved clipped turbine and shaft, while still keeping the k04 core, this is not so easy to do. This K16 turbine gives much lower back pressure and keeps EGT lower compared to stock K04 turbine or clipped stock.
The clipping of the K16 turbine reduces blade area thus increasing gas flow and so reducing back pressure and lowering exhaust gas temperatures, allowing safer higher boost level's. This process also gives a secondary advantage of removing some material, lightening the turbine thus reducing rotational mass improving moment of inertia. Dyno's have shown little loss in response vs stock K04 yet huge gains in power and torque.
Special TTE developed in house 360 deg high performance motorsport journal bearing system is fitted. Durable at high loads with no loss in transient response.
Actuator used is uprated sprung OE unit, fitted with TTE's reinforced clamps for trouble free operation.
Precisely balancing our turbochargers is a key critical factor to become a TTE upgrade unit as longevity and performance are paramount. Good balance improves acoustics also. Subsequent great care is taken with all TTE turbochargers to achieving their balance standards. Firstly, parts are balanced at slow speeds up to 2800RPM in multiple planes using TTE's single parts machine, then components are assembled and then the CHRA are dynamically balanced, but this time depending on application at up to 250,000 RPM in multiple planes using their in house VSR machine to acquire the ultimate equilibrium, to a standard far higher than OEM. Each turbocharger is supplied with serial numbered balance test result document.
Engine internals: Rods/Bearings and Pistons/Rings are recommended (above approximately 400 WHP, especially on race gas)
Intake: A high flow quality intake system that replaces the factory air box is required.
Exhaust: A high flow downpipe is required but the catback exhaust may remain unmodified.
Intercooler: An intercooler upgrade is required.
High Pressure Fuel Pump: A high pressure fuel pump upgrade is required.
Valve Springs: Upgraded valve springs may be required if valve float is exhibited.
Spark Plugs: NGK BKR8EIX spark plugs gapped to 0.022" ±0.002" or 0.55mm ±0.05mm with a change interval of 10-15,000 mi or 16-24,000 km.
Transmission: TCU or clutch and flywheel upgrade is highly recommended.