The Ckra Engine, a 140ps 2.0 TDI workhorse found in US and Canadian VW Passat models, presents a fantastic platform for diesel performance tuning. At keyfobprog.com, we specialize in unlocking the hidden potential of engines like the CKRA. This guide provides a definitive roadmap for upgrading your CKRA engine, enhancing power and driving experience while focusing on reliable and effective modifications.
The initial and most impactful upgrade for your CKRA engine is a custom ECU remap. Even with completely stock hardware, a professional tune can liberate approximately +30 BHP. This is achieved by optimizing parameters within the engine control unit (ECU) to safely increase performance without requiring any physical modifications.
For those seeking more substantial gains, further modifications can be implemented in stages.
Emissions Control Removal: Considerations for CKRA Engine Tuning
Before proceeding with any modifications to your emissions control systems, it’s crucial to understand local regulations. Laws regarding the removal or disabling of emissions control devices vary significantly by region. Always verify the legal implications in your area before undertaking such modifications.
For CKRA engines, we offer two primary kits targeting emissions controls:
- EGR Delete Kit: This kit allows for the removal of the Exhaust Gas Recirculation (EGR) system.
- EGR & DPF Delete Downpipe Kit: This comprehensive kit includes EGR removal and a Downpipe to eliminate the Diesel Particulate Filter (DPF).
Important Note on DPF and EGR: The EGR system plays a vital role in active DPF regeneration. We strongly advise against deleting the EGR without also addressing the DPF. Removing the EGR alone can lead to DPF blockage over time, necessitating costly repairs.
DPF removal can be achieved by either gutting the stock downpipe or installing our performance stainless steel downpipe, as featured below.
CKRA EGR Delete Kit: Enhance your VW TDI engine performance by removing the EGR with this kit.
CKRA EGR & DPF Delete Downpipe: Upgrade your CKRA engine with this kit for enhanced performance by removing EGR and DPF.
Turbo Upgrades for CKRA Engines: Unleashing More Horsepower
Once emissions equipment is addressed and a custom tune is in place, the factory turbocharger becomes the next limiting factor in CKRA engine performance. We offer staged turbo upgrades to suit different power goals.
For a modest increase while retaining emissions compliance (using the stock downpipe) or further enhancing a delete setup, our bolt-on turbo upgrade is an excellent choice.
This 200BHP Turbo Upgrade directly replaces the stock unit and, when paired with custom tuning, can deliver approximately 200 horsepower.
For CKRA engine enthusiasts aiming for significantly higher power outputs in the range of 230-290 BHP, we recommend the GTB2260VK turbo upgrade. The GTB2260VK is renowned as one of the best street turbos for the CKRA platform, offering a safe and substantial power increase.
200BHP Turbo Upgrade for CKRA Engine: Achieve 200HP with this bolt-on turbo upgrade for your 2.0 TDI CKRA engine.
GTB2260VK Turbo Kit for CKRA Engine: Upgrade your CKRA engine to 230-290BHP with this high-performance GTB2260VK turbo kit.
Fuel System Enhancements for High-Power CKRA Builds
The CKRA engine is factory-equipped with a CP4.1 R40 fuel pump. This pump can support power levels up to approximately 230-240 BHP. For a marginal increase of 5-10 BHP within this range, an upgraded metering valve can be installed.
However, the CP4 fuel pump is known to have reliability concerns, particularly in regions with lower quality fuel. For enhanced reliability or to achieve power outputs exceeding 240 BHP, upgrading to a CP3 fuel pump is highly recommended.
For CKRA engine builds targeting 300 BHP and beyond, a CP3 fuel pump conversion is essential.
After installing a CP3 pump, recalibrating the engine tune is necessary to optimize fuel delivery.
The stock fuel injectors on the CKRA engine are generally sufficient for power levels up to around 260 BHP. Beyond this threshold, we advise upgrading to our Stage 1 Solenoid Injector upgrade to ensure adequate fuel delivery for higher horsepower targets.
CP4 Metering Valve (90°) for CKRA Engine: Improve fuel flow in your CKRA engine with this 90-degree CP4 metering valve upgrade.
CP3 Fuel Pump Conversion for CKRA Engine: Essential for 240BHP+ CKRA builds, upgrade to a reliable CP3 fuel pump.
Injector Upgrade for CKRA Engine: Required for 260BHP+, upgrade your injectors for high-performance CKRA tuning.
2700 BAR Fuel Pressure Sensor Upgrade: Enhance your CKRA fuel system with this genuine VAG 2700 BAR fuel pressure sensor.
Charge Cooler/Intercooler Considerations for CKRA Tuning
The CKRA engine utilizes a charge air cooler rather than a traditional intercooler. Our testing indicates that the stock charge air cooler is adequate for maintaining charge air temperatures within acceptable limits, even with performance tuning. Therefore, an intercooler upgrade is generally not necessary for CKRA engine modifications.
Transmission and Clutch Upgrades for CKRA Engine Performance
A significant portion of CKRA-equipped Passats are fitted with the DSG (02E DQ250) transmission. This gearbox is remarkably robust and exhibits no common reliability issues, even at power levels of 280-300 BHP. The DQ250 DSG does not typically require clutch or flywheel upgrades within this power range. However, DSG tuning is recommended to increase clutch pressure to effectively handle the increased torque output.
For CKRA Passats equipped with a manual transmission (02Q 6-speed), the gearbox itself is also very reliable. The stock dual mass flywheel and clutch kit are generally sufficient for up to 200 BHP, assuming they are in good condition. For power levels exceeding 200 BHP, we recommend upgrading to the Sachs SRE clutch kit.
Some CKRA owners have reported successfully running 220-230 BHP on the stock clutch without encountering issues. However, for optimal reliability and longevity, an upgrade is advisable at these higher power levels.
DSG 02E DQ250 Components:
Replacement DSG Clutch – 02E398029C: Genuine 02E DSG clutch pack for 6-speed transmissions.
Replacement DSG Flywheel – 03L105266DE: LUK flywheel for 2.0 TDI DSG 6-speed automatic transmissions.
Manual 02Q 6 Speed Components:
Sachs Stock Replacement Clutch Kit: Sachs dual mass flywheel and clutch kit for 2.0 TDI 6-speed manual 02Q vehicles.
Sachs SRE Race Clutch Kit: Sachs DMF SRE clutch kit for high-performance CKRA and Bluemotion 2.0 TDI engines.
02Q Short Shifter: Genuine 02Q 6-speed gearbox short shift kit for enhanced shifting feel.
Remote CKRA Engine Tuning Services Available
No matter your location, our remote tuning service allows us to optimize your CKRA engine’s performance using our Powergate system. To obtain pricing for Powergate tuning tailored to your CKRA engine, simply create an account on our website and input your VIN/Chassis number.
Our tuning solutions are not generic; they are custom-developed for each specific ECU. To ensure optimal results with remote tuning, we require comprehensive data logs from your vehicle. This necessitates the use of a working VCDS / VAG-COM diagnostic tool to provide us with the necessary data.
For more detailed information about our Powergate system and remote tuning capabilities, please explore the links provided below.
Powergate Tool for Remote Tuning: Darkside Powergate 3 user unit for remote ECU tuning of your CKRA engine.
Powergate Remote Tuning Service: Darkside Powergate remote tuning service for optimizing your CKRA engine’s performance.
Genuine VAG-COM / VCDS Diagnostic Tool: Essential VAG-COM / VCDS software for data logging and diagnostics on VW, Audi, Seat, and Skoda vehicles, required for custom CKRA tuning.
Note: VCDS access is not required if you are solely using the Powergate system for pre-defined functions such as DPF/EGR software removal.
21 01 2023
