01/03/2011
For enthusiasts and drivers of VW, Audi, SEAT, and Skoda models equipped with the 2.0 16v TDI BKD engine, the pursuit of enhanced performance is a common goal. This robust engine, while capable in its standard form, truly comes alive with the right modifications. One of the most impactful upgrades available is a comprehensive turbocharger kit, designed to transform your vehicle into a formidable performer on the road. This article delves into the specifics of the BKD engine, addresses common perceptions about its reliability, and thoroughly explores a leading GTB turbo kit that promises significant power gains while maintaining excellent daily drivability.
Understanding the BKD Engine
The BKD engine is a 2.0-litre, 16-valve Turbocharged Direct Injection (TDI) unit, primarily found in various VAG group vehicles produced between 2004 and 2009. Often referred to as the PD140 due to its original 140 horsepower output, it's a common sight in popular models across the Volkswagen, Audi, SEAT, and Skoda ranges. Its widespread adoption speaks volumes about its fundamental design and utility as a workhorse diesel engine.
Is the BKD Engine Reliable? Addressing Common Concerns
Discussions on automotive forums often raise questions about the reliability of the 2.0 TDI engine, specifically mentioning issues with oil pumps, injectors, and cylinder heads. However, it's crucial to differentiate between various 2.0 TDI engine codes. When it comes to the BKD, many of these broader 2.0 TDI concerns do not apply. According to expert insights, the BKD engine is, in fact, an intrinsically very reliable unit, despite some common issues that can arise.
The primary concerns specifically associated with the BKD engine are typically related to the flywheel and the turbocharger. Dual-mass flywheels on BKD engines can occasionally break or develop rattles, leading to a poor idle and necessitating replacement of both the flywheel and clutch. Furthermore, the standard turbochargers on BKD units have been known to wear out or clog up relatively easily, even at low mileage, leading to issues like howling or overboosting. These repairs can be costly, often in the region of £900 to £1000. While these issues are known, it's important to remember that the BKD was a "massively utilised engine," meaning the sheer number of units in circulation makes any reported problems seem more widespread than they might truly be on a percentage basis. Instances of porous cylinder heads, a concern with some other 2.0 TDI variants, have been reported as rare and declining for the BKD in recent years.
For those considering a BKD-powered vehicle, especially in the 2004-2006 year range, it’s worth noting that while issues can occur, they are not universal, and the engine's fundamental reliability remains strong. Regular maintenance and attentive driving, including occasionally "giving a car a good workout" to help clear out turbo cobwebs, can contribute to its longevity.
Introducing the GTB2260VK Turbo Kit for BKD Engines
For owners looking to significantly boost the performance of their BKD-equipped vehicle, the GTB2260VK Turbo Kit offers a compelling solution. This kit is specifically designed as a direct bolt-on kit for the 2.0 16v TDI BKD engine, making a powerful conversion more accessible than ever. It's not just about raw power; the kit is engineered for perfect daily drivability, ensuring that your enhanced vehicle remains a pleasure to use for everyday journeys.
The kit is compatible with a range of popular VAG models that house the BKD engine (2004 - 2009), including:
- VW Golf Mk5
- VW Jetta
- Audi A3
- SEAT Leon Mk2
- SEAT Toledo
- SEAT Altea
- Skoda Octavia Mk3
This comprehensive kit is considered a true 'Bolt-On' Big Turbo conversion that is also future-proof. Its design allows for straightforward upgrades to more powerful turbos within the GTB series without needing to replace the entire pipework, making it a flexible investment for performance enthusiasts.
What's Included in the Kit?
The GTB2260VK Turbo Kit is a complete package, providing all the essential components required for installation. This meticulous attention to detail ensures a smooth and successful upgrade process. Key components include:
- Brand New Garrett GTB Turbocharger (specific model depending on option chosen)
- Brand New Vacuum Actuator with GTB Vacuum Conversion Service
- Laser Cut and CNC Folded Stainless Actuator Bracket
- Stainless Tubular Exhaust Manifold
- 3” Stainless Downpipe with Stainless 4" Flexi and Dual Fitment Flange
- Braided Oil Feed Line
- Genuine VW OEM Oil Return Line
- Silicone Turbo Inlet Pipe Connector Hose with clamps
- Silicone Boost Outlet Hose with clamps
- Genuine VW OEM Manifold Gasket
- Genuine VW OEM Turbo Gasket
- Genuine VW OEM Downpipe Gasket
- Genuine VW OEM Oil Return Gasket
- All other nuts and bolts required for fitment
The included silicone hoses are specifically designed to integrate seamlessly with the standard intercooler pipework and the Turbo Inlet Pipe (TIP). Furthermore, the 3" Downpipe is engineered for a perfect fit with common aftermarket exhaust systems, such as the Milltek 2.75" systems.
Turbocharger Options and Power Potential
One of the standout features of this kit is the flexibility it offers through various GTB turbocharger options. There are four distinct models available: the GTB1756VK, GTB2056VK, GTB2260VK, and a custom GTB2265VK Hybrid. All these turbos are completely interchangeable within the kit. This means you can start with a smaller turbo, like the GTB1756VK, and easily upgrade to a larger unit later by simply swapping the turbocharger itself, with all existing pipework bolting right up.
The power figures achievable with these turbos are impressive, assuming appropriate supporting modifications are in place. These figures represent what is generally considered achievable under 'safe' parameters, balancing injection duration, exhaust gas temperature, and exhaust manifold pressures. While greater power has been achieved in some instances, it often involves pushing components beyond their safe operating limits.
Turbocharger Power Output Comparison
| Turbo Model | Boost Pressure (PSI) | RPM (Approx.) | Estimated BHP |
|---|---|---|---|
| GTB1756VK | 32 | 2000 | 230 |
| GTB2056VK | 34 | 2300 | 260 |
| GTB2260VK | 35 | 2600 | 310 |
As a real-world example of the kit's capability, a Jetta 2.0 TDI PD140 equipped with just the GTB2260VK turbo kit, an EGR Delete, Milltek Exhaust, and an S3 Intercooler, achieved a remarkable 235bhp and 330Ft/Lbs. With the addition of Race PD injectors, the expectation is to surpass 280hp, with a fully worked head potentially pushing output beyond 300hp.
Advanced Turbocharger Technology
The GTB series turbos incorporate the latest 3rd Generation VNT System. This advanced variable nozzle turbine technology is far superior to previous systems, delivering quicker spool-up times and lower manifold pressures at high RPMs compared to older 1st Generation turbos. This technological advantage contributes significantly to both the performance and drivability of the upgraded engine.
Turbocharger Wheel Sizes Comparison
| Turbo Model | Compressor Inducer (mm) | Turbine Exducer (mm) |
|---|---|---|
| GTB1756VK | 42.5 | 39.5 |
| GTB2056VK | 46.5 | 42.5 |
| GTB2260VK | 50.5 | 45.5 |
| GTB2265VK Hybrid | 52.5 | 47.5 |
| (Popular Older Turbo 1) | ~38.0 | ~34.0 |
| (Popular Older Turbo 2) | ~40.0 | ~36.0 |
Supporting Modifications for Optimal Performance
While the GTB turbo kit is a significant upgrade on its own, achieving the higher power figures mentioned requires appropriate supporting modifications. These include:
- EGR Delete: Removing the Exhaust Gas Recirculation system can improve airflow and reduce carbon build-up.
- Upgraded Exhaust System: A less restrictive exhaust, such as a 2.75" or 3" system, allows for better exhaust gas flow, reducing back pressure and improving turbo efficiency.
- Larger Intercooler: An upgraded intercooler (e.g., an S3 intercooler) is crucial for cooling the denser charge air produced by the larger turbo, preventing power loss due to heat soak.
- Performance Injectors: For power levels exceeding 250bhp, upgraded injectors (e.g., Race PD injectors) are often necessary to deliver sufficient fuel.
- Worked Cylinder Head: For extreme power figures (300hp+), a fully worked cylinder head may be required to improve flow and withstand higher stresses.
- Engine Tuning: A custom ECU remap is absolutely essential to safely integrate the new turbocharger and supporting modifications, optimising fuel delivery, boost pressure, and other engine parameters for maximum performance and reliability.
Frequently Asked Questions (FAQs)
Which cars will fit a BKD kit?
The GTB turbo kit for the BKD engine is designed to fit a range of VAG vehicles from 2004 to 2009. These include the VW Golf Mk5, VW Jetta, Audi A3, SEAT Leon Mk2, SEAT Toledo, SEAT Altea, and Skoda Octavia Mk3, provided they are equipped with the 2.0 16v TDI BKD engine.
Is the BKD a good engine?
Despite some common misconceptions and forum discussions, the BKD engine is considered an intrinsically very reliable unit. While it can suffer from specific issues like flywheel and turbocharger wear, these are generally manageable, and the engine was massively utilised across many popular VAG models due to its robust design.
What are the common BKD engine problems?
The most commonly reported issues with the BKD engine are related to the dual-mass flywheel, which can break or rattle, and the standard turbocharger, which can wear or clog up relatively easily. Porous cylinder head issues, while a concern for some 2.0 TDI variants, are reported as rare for the BKD and have become less common in recent years.
How much BHP does a Profidiesel turbo kit make?
The power output from a Profidiesel GTB turbo kit depends on the specific turbocharger chosen and the supporting modifications. For instance, the GTB1756VK can achieve around 230bhp, the GTB2056VK approximately 260bhp, and the GTB2260VK can push beyond 310bhp. With further modifications like race injectors and a worked head, over 300bhp is achievable, depending on the engine's condition and tuning.
Are the turbos in the kit interchangeable?
Yes, one of the key advantages of this kit is the interchangeability of the GTB series turbochargers. The GTB1756VK, GTB2056VK, GTB2260VK, and GTB2265VK Hybrid units are all designed to fit the existing pipework within the kit. This allows for easy upgrades by simply swapping the turbocharger unit itself.
What supporting modifications are needed for this turbo kit?
To maximise the potential of the GTB turbo kit, especially for higher power outputs, supporting modifications are highly recommended. These typically include an EGR Delete, an upgraded exhaust system (e.g., 3-inch downpipe and full exhaust), a larger intercooler (like an S3 intercooler), and potentially upgraded injectors (e.g., Race PD injectors) and a worked cylinder head for very high power targets. A custom ECU remap is essential for all performance stages.
Conclusion
The BKD engine, despite some historical concerns, remains a solid and reliable platform for performance tuning. With the advent of comprehensive, direct bolt-on turbo kits like the GTB series, unlocking significant power gains has become more accessible and reliable than ever. Whether you're aiming for a modest increase in performance for daily driving or a substantial power boost for track days, the flexibility and engineering of these kits, combined with appropriate supporting modifications, allow BKD owners to truly transform their vehicles. Investing in such a kit not only enhances your driving experience but also future-proofs your vehicle for further upgrades, ensuring your BKD-powered car can deliver thrilling performance for years to come.
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