.: Polo TDI Sportline Turbo Upgrade and FMI Install :.

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.: Polo TDI Sportline Turbo Upgrade and FMI Install :.

Post by EedubzShmeedubz » Sat Mar 31, 2007 10:17 pm

So Friday saw Chicken Licken arrive back in SA for a little surpirse visit from Denmark. One of his priorities was to get some work done to his car while here, so the work began...

The parts were collected (thanx Tashen :wink: ) on Friday shortly after Chicken's arrival, and were promptly laid out an admired. Chicken sat in his car for 3 hours making "vroom vroom psshhhhh" sounds with the turbo on his lap :lol:

The turbo in question was a Garrett VNT1749VB - PD150 from the SEAT Cupra TDI. This would replace the OEM Garrett VNT1749V

The Parts
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The Garrett VNT1749VB
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So at about 9am on Saturday we met G60 at Zabka to do the install.
On a side note, Chicken had decided that the night of his arrival would be a good time to indulge, so the morning was abit rough for him, with many grunts and groans emminating from him.

After a short chat we started with the work and got the car jacked up on the lift.
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G60's tools for the job
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Morne quickly got to work and removed the TDI engine cover. I was surpirsed that it simply pulled off, I thought a few screws would need to be loosened, but that was not the case.
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One of the first things to be removed was the airbox and the piped on the intake pipe to the turbo
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The intake manifold was then removed
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Roadhawg and G60 having a chat. Its amazing how much [email protected] guys can talk when they spend a day together working on cars. If the walls of that workshop could talk :wink: :shock: :?
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The old turbo. The oil on the exhaust manifold is lube to loosen up the bolts
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Some of the parts removed so far
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Cool old tractor outside
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Cool new tractor outside :wink:
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One of many smoke breaks. I didnt feel left out tho 8)
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We needed a few odds and ends, and this is where we found them!!! :twisted:
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The old turbo being removed
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The two turbos side by side. The new VB on the left, old V on the right
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New VB on right, old V on left
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G60 grining something
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New turbo in place :D
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My, how time flies...
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Did you know, if u drop the bolt that holds the intake pipe in place you have to remove the battery and basically climb into the engine bay to retrieve it :P
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The new intercooler
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The front bumper comes off
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The really tiny OE intercooler tucked away on the driver's side of the car
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Chicken was obsessed with cleaning everything as it was exposed :roll:
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The new FMI (Front Mount Intercooler) mock fitted to see what goes where and how we would run the boost piping
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Some piping being fabricated
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Next the front valance had to be removed to mount the FMI
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Holes were drilled for the FMI mounts...
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...and the mounts were attached
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The FMI in place
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A small section of the front valance had to be cut away to accomodate the FMI
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Front valence goin back on
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The "watcher"
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It was bit of a mission figuring out how to route the boost piping, but we eventually figured it out. Basically the charge comes from the turbo, into the new FMI, then into the smaller OE cooler, and then up top to the intake manifold
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Front bumper back on
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The finished product :twisted:
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A very happy Chicken Licken :D
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The end of a very fullfilling day 8)
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At the moment the new turbo is still boosting at the same levels as the OE turbo. The car will recieve an FRC remap in the next week or so, and after that it will be boosting much higher and will be able to take full potential of the new setup 8)

I had a great day and I think so did G60, Roadhawg and Chicken. I learnt alot from G60, and really enjoyed talking about the technical aspects of cars. I also loved the ride in this car afterwards, Roadhawg will agree with me that its an amazing beast of a car :twisted:
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Post by RoadHaWg » Sat Mar 31, 2007 10:34 pm

Hehe!!

Nice one man.

Yeah Had fun today guys. Nice seeing the inside of a TDi, and the info that G60 gave me that didnt go over my head I am very grateful for!!

But Eedubz....U forgot a couple steps there man....I think they went: Bumper on.....Bumper off.....Bumper on.....Bumper off.....Bumper on....etc!!!


I'll be happy to get in ur way again anytime guys!!
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Post by g60 golf » Sat Mar 31, 2007 10:45 pm

Guys shot for letting me do this.
I wanted to see how this all came together and how it looked.
im impressed with the turbo.Iwish vw would do this to all there 1.9 will last longer.

Don't mention front bumper. :twisted:

Eedubz shot for all the photos and help.
Rdhawg and chicken shot to u guys too.

Whats next?
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Post by MeTsU » Sat Mar 31, 2007 10:50 pm

Hey Chicken,

Glad to see that your mod finally became a reality. ;) See, I kept my word. ;)
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Post by RoadHaWg » Sat Mar 31, 2007 11:02 pm

g60 golf wrote:Guys shot for letting me do this.
I wanted to see how this all came together and how it looked.
im impressed with the turbo.Iwish vw would do this to all there 1.9 will last longer.

Don't mention front bumper. :twisted:

Eedubz shot for all the photos and help.
Rdhawg and chicken shot to u guys too.

Whats next?
Whats next u say.....

Think that cooler will fit behind one of these bumpers?
Image
8) :lol:

Man today was an eye opener. Thanks again.

And chicken.....cant wait to see what she does when she's got some software!!
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"We've all been raised on television to believe that one day we'd all be millionaires, and movie gods, and rock stars. But we won't. And we're slowly learning that fact. So we build VDubs son..."

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Post by PhatDub » Sat Mar 31, 2007 11:27 pm

those are really good pics eedubz

chickenlicken, congrats on the upgrade and look forward to the dyno sheets after the software has been done
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Post by Exigo » Sun Apr 01, 2007 8:03 am

Interesting pictorial - while you had the intake manifold off - did you get a chance to look inside and if/how gunky the thing was...just interested in terms of our superior local fuel quality.
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Post by Chicken Licken » Sun Apr 01, 2007 4:08 pm

Thanks guys :)

It was a great day with Stu, Morne and Sean all in all ...

It too some fancy foot work to organise everything while I was in Denmark. This was all organised via PM’s, MSN, SMS’s and Email :wink: … So no one can say things can’t be done remotely :wink:

I gained so much knowledge about the diesel and what it is and capable of. As per G60 ... The 1.9 TDI block is bullet proof ... it's just the cooling, plumbing and ECU management that needs attention and before you know it you got a high spec hatch :twisted:

@ Eedubz - Dude ... thanks man, having you there really helped IMHO, from the balancing of time taking pictures and helping out with the logistics etc of the intercooler and placement of the pipes. Truly thankful for the help mate :wink:

@ RH - Nice One dude yesterday on pulling through it was lank helpful with delegating and sorting out piping too ... 8)

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^^^ I think It will fit Stu, check the lower tubing of panels on the left hand side … looks to be wide enough … Need to really see it in the flesh though :?

When she’s off the OEM map and loaded with the juice …:twisted: - You … Me … TLGP :twisted:

@ G60 - You made it all happen ;) ... I would not have the job done by anyone else. Your work is so meticulous and clean man! You have carnal knowledge of VW’s that even to this minute make me think if I could just plug in your brain and download your VW file that would be super! :D

Next on the cards is FRC (awaiting Preggie to return to SA from a quick trip abroad) – and yes … you got dib’s on a spin ;) :D btw - A special thanks to Tony for the use of his Garage please Morne :wink:

@ MeTsU – Top man! :D … Nice one for keeping things under wraps for so long. Hehe

@ PHATBOY - Thanks dude … ;) … Me too man … I think at the moment it’s about just over 100kw atw with the bigger turbo. Can feel a nice ‘kick’ when up to speed even with the stock OEM map.

@ Exigo – I asked Morne and he said It was quiet clean … hardly any gunk up. Personally I change oil every 7 500 km’s for good practice and ONLY Sasol ULS 50 ppm on fillup, I've done this since the day I drove it off the floor at 0km to now which is 26 300km on the clock.

Now - for a report back on the drive of the car. :)

- The Spool up in the plumbing takes a tad longer now with the added pull through the system of air cause of the intercooler. (Expected). Morne said the software will sort that out. (Yaay :D )
- Due to the delayed spooling the boost kicks in at 2.2k as before it was 1.9k (Expected). Morne confirmed that the software will also sort this out.
- The pull through the rpm range is stronger and longer, the Nm feels like it has more punch than before … Now you can only imagine what goes through your head on the post work the FRC map :twisted:

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^^^ Yes … It’s that nice to look at :D

Thanks to the 3 boy’s that took there Saturday out to do this. It was really a great experience (and sometimes challenging ;) ) … We do not speak of how much we removed the bumper :lol:

8)
Sean

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Post by g60 golf » Sun Apr 01, 2007 4:20 pm

There is one pic missing her though.

EEDUBZ with the ring round his mouth after blowing on the pipes. :P

Guys it was a long day but was fun at the same time.

Let me know when the frc map is on mate. :twisted:

Now its roadhoags turn??????
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Post by RoadHaWg » Sun Apr 01, 2007 4:49 pm

g60 golf wrote:
Now its roadhoags turn??????
Yeah im saving...trust me.

But i think the VNT17 is too easy for u man.....VNT 20 will be more of a challenge!! :wink:
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Post by Neuk » Sun Apr 01, 2007 5:25 pm

Hey boys

Nice work :!: Wish I could have been there to see this is I am planning on something similar when my car warranty/motorplan expires :D Saw the car in the flesh today and she looks awesome :D The intercooler looks really good behind the mesh and doesn't stand out in a ricy way at all :!: As Chicken said the 1.9 TDi engine is pretty much bomb proof, just the turbo and cooling that needs some work and software will always help :!: I can definately feel the effects of heat on my TDi during summer and the intercooler can only help :!:

I look forward to the updates once the new software has been installed and properly run in :D Oh - And I would like a drive someday :twisted:

@ G60 - As always, great work and great to have guys like yourself around to lend a helping hand :D I will definately be coming to you for help and suggestions/recommendations when I decide to do similar work on my TDi :D

Cheers
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Post by RoadHaWg » Sun Apr 01, 2007 7:06 pm

Neuk wrote:Hey boys

Nice work :!: Wish I could have been there to see this is I am planning on something similar when my car warranty/motorplan expires :D Saw the car in the flesh today and she looks awesome :D The intercooler looks really good behind the mesh and doesn't stand out in a ricy way at all :!: As Chicken said the 1.9 TDi engine is pretty much bomb proof, just the turbo and cooling that needs some work and software will always help :!: I can definately feel the effects of heat on my TDi during summer and the intercooler can only help :!:

I look forward to the updates once the new software has been installed and properly run in :D Oh - And I would like a drive someday :twisted:

@ G60 - As always, great work and great to have guys like yourself around to lend a helping hand :D I will definately be coming to you for help and suggestions/recommendations when I decide to do similar work on my TDi :D

Cheers
Nic
Me and you both man. Maybe we do a Ying + Yang dual project! 8) :lol:

Oh and we need to come up with some serious quantum physiscs **** to make a new cooler fit in our bumpers dude!! Its tighter than.....than.... (Due to lack of "P.C." expressions) Something really tight in there!!
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Post by Rabbit222 » Sun Apr 01, 2007 7:21 pm

Chicken! Well done bru, i'm really impressed with what ALL of you okes pulled off...brilliant I tell you!

@ Eedubz, shot for the pics bru...as always you don't dissappoint!
@ HaWG...your car is looking super sexy bru!
@ Morne', Dude you are without doubt the best mechie out there..keep up the great work buddy!
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Post by GB9 » Sun Apr 01, 2007 8:28 pm

Unbelievable work right there :shock:

Chicken, how much did this set you back if you don't mind me asking? The FMIC looks wicked under that front bumper! Morne, would an FMIC fit under a stock F/L sportline?

You should maybe get something together and rival SAC with a bigger turbo/FMIC/Chip package of your own! I'd be a customer velly soon!
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Post by Chicken Licken » Sun Apr 01, 2007 8:30 pm

Rabbit222 wrote:Chicken! Well done bru, i'm really impressed with what ALL of you okes pulled off...brilliant I tell you!
Thanks Shaun :D Means alot coming from the guru of mod's himself :wink: :)
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Post by Chicken Licken » Sun Apr 01, 2007 8:40 pm

GB9 wrote:Unbelievable work right there :shock:

Chicken, how much did this set you back if you don't mind me asking? The FMIC looks wicked under that front bumper! Morne, would an FMIC fit under a stock F/L sportline?

You should maybe get something together and rival SAC with a bigger turbo/FMIC/Chip package of your own! I'd be a customer velly soon!
Price You have PM 8)

I does fit on the FL SL ... the bumper is more rounded and allows for the space ... the only reason why it 'fitted' mine (with some minor cutting and pasteing) was the Sportech lower bumper piece ... It's way more roomy than the OEM pre-face. :idea:
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Post by g60 golf » Sun Apr 01, 2007 9:53 pm

Chicken is right it will fit the face lift.
In the pre face lift the cooler will have to be longer and flater
also the carrier might need to be cut to let the pipe work through.

This setup on Chickens car is very nice and neat.

Why oh why can't the factry do this??? :lol: :cry:
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Post by Chicken Licken » Sun Apr 01, 2007 10:53 pm

g60 golf wrote:Chicken is right it will fit the face lift.
In the pre face lift the cooler will have to be longer and flater
also the carrier might need to be cut to let the pipe work through.

This setup on Chickens car is very nice and neat.

Why oh why can't the factory do this??? :lol: :cry:
I concur batman ... :roll:

We should do a expose' to VWSA on upping power while maintaining ice particles shooting into the turbo intake with this setup :lol:

Thanks again Morne :o Can't stop saying thanks :P But it's something that never gets tiresome 8) :D

Oh ... and you have PM 8)
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Post by Tashen » Sun Apr 01, 2007 11:43 pm

It was my pleasure 8)
Cant wait to see how your car runs with the new map loaded.

@G60 : Morne your work is excellent. I'll definitely be bringing my GTi to you in the not so distant future for a beeger turbo conversion.

@Eedubz : Great pics buddy. :wink:
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Post by RoadHaWg » Sun Apr 01, 2007 11:50 pm

Tashen wrote:It was my pleasure 8)
Cant wait to see how your car runs with the new map loaded.

@G60 : Morne your work is excellent. I'll definitely be bringing my GTi to you in the not so distant future for a beeger turbo conversion.

@Eedubz : Great pics buddy. :wink:
Tashen bru!

How much did u get charged to return ur car to standard? Coz who ever told u it was a str8 bolt on conversion was telling porky pies!!
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"We've all been raised on television to believe that one day we'd all be millionaires, and movie gods, and rock stars. But we won't. And we're slowly learning that fact. So we build VDubs son..."

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Post by *ace* » Mon Apr 02, 2007 8:32 am

:shock: :shock:
Well done guys!
Cant wait to see what she does with the FRC... YOH!
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Post by Cupra_Ary » Mon Apr 02, 2007 9:04 am

Hey Chicken - U skelm U :wink:
Wow dude, Nice to know we have some TDI die hards willing to mod their cars.

I'm sure ur car is going to fly and make some serious HP bro. Nice work.

Well done G60 (Morne'), ur work is outstanding as usual. We hope one day u open a Workshop, and I'll be ur 1st customer.

EeDubz - Great pics as usual too.

RoadHaWg - When u doing the mods boet?
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Post by RoadHaWg » Mon Apr 02, 2007 9:18 am

Polo_Ary wrote: RoadHaWg - When u doing the mods boet?
im busy trying to work out which body parts i can do without!
both mine and the cars! :lol: :lol:
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"We've all been raised on television to believe that one day we'd all be millionaires, and movie gods, and rock stars. But we won't. And we're slowly learning that fact. So we build VDubs son..."

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Post by Tashen » Mon Apr 02, 2007 9:24 am

RoadHaWg wrote: Tashen bru!

How much did u get charged to return ur car to standard? Coz who ever told u it was a str8 bolt on conversion was telling porky pies!!
:lol: Well the turbo is a direct bolt on...the intercooler not so str8 bolt on :lol:
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Post by RoadHaWg » Mon Apr 02, 2007 9:35 am

Tashen wrote:
RoadHaWg wrote: Tashen bru!

How much did u get charged to return ur car to standard? Coz who ever told u it was a str8 bolt on conversion was telling porky pies!!
:lol: Well the turbo is a direct bolt on...the intercooler not so str8 bolt on :lol:
Hehe. good answer!!!
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2014 KTM 1190 Adventure
No Mk1 ;(
"We've all been raised on television to believe that one day we'd all be millionaires, and movie gods, and rock stars. But we won't. And we're slowly learning that fact. So we build VDubs son..."

"Owning a MK1 varies between having sex to getting hit in the balls. Usually several times in one day."
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