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

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savage
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Post by savage » Mon Apr 02, 2007 9:42 am

Very nice your car looks great, thanks for posting the pics gives me an idea of what my turbo looks like. Nice meeting you yesterday aswell , keep us updated on what power she produces after the software :wink:
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2007 BMW Z4 3.0si Coupe

Ex: 2007 Opel Astra GTC 1.9 CDTI Sport
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Ex: 2003 Astra 2.2 Gsi
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Post by Chicken Licken » Mon Apr 02, 2007 10:19 am

Thanks all for the great comments :) I hope to get the ECU sorted soon and then dyno. I'm also keen on 2 dyno runs ... as it it now and after the juice upload

@ Ary ... U ... Me ... and the tar-mac dude :twisted:

@ savage - for sure dude ... Nice meeting your yesterday aswell, remember ... all one big happy family of cuzzin's, I've got some SEAT blood in my VW now 8)
Sean

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Post by RoadHaWg » Mon Apr 02, 2007 10:24 am

Chicken Licken wrote:Thanks all for the great comments :) I hope to get the ECU sorted soon and then dyno. I'm also keen on 2 dyno runs ... as it it now and after the juice upload

@ Ary ... U ... Me ... and the tar-mac dude :twisted:

@ savage - for sure dude ... Nice meeting your yesterday aswell, remember ... all one big happy family of cuzzin's, I've got some SEAT blood in my VW now 8)
And dont forget the toyota bolt!! :P :P
Stuart
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1966 Splitty.
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..."

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Post by Chicken Licken » Mon Apr 02, 2007 10:27 am

RoadHaWg wrote: And dont forget the toyota bolt!! :P :P
:lol: Damb tin-can bolt :evil: ... some random size hey Stu? Like 12.5 or something :P
Sean

Daily & Vent:
'14 SG FORD Wildtrak 4x4 - 'Stockish'
'94 OB VR6 - Stock
Ex:
'14 PW
GTI - 'Stock' - SOLD
'07 UG GTI - Modified - SOLD

"Lending my cars to you is a bit like lending your girlfriend to a porn star. Yes, you'll get her back but you just know she'll never be the same again... she'll always be wanting more"
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Post by savage » Mon Apr 02, 2007 10:41 am

Chicken Licken wrote:Thanks all for the great comments :) I hope to get the ECU sorted soon and then dyno. I'm also keen on 2 dyno runs ... as it it now and after the juice upload

@ Ary ... U ... Me ... and the tar-mac dude :twisted:

@ savage - for sure dude ... Nice meeting your yesterday aswell, remember ... all one big happy family of cuzzin's, I've got some SEAT blood in my VW now 8)
We will have to call your car a VEAT then :lol:
Image

2007 BMW Z4 3.0si Coupe

Ex: 2007 Opel Astra GTC 1.9 CDTI Sport
Ex: 2007 Seat Ibiza Cupra 1.9 TDI
Ex: 2003 Astra 2.2 Gsi
Ex: 2002 Corsa Gsi Ltd
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Post by Cupra_Ary » Mon Apr 02, 2007 11:55 am

Chicken Licken wrote:@ Ary ... U ... Me ... and the tar-mac dude :twisted:
Schweeeeet bud,
Can't wait!

How long r u here bud?
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Post by Chicken Licken » Mon Apr 02, 2007 3:21 pm

Polo_Ary wrote: Schweeeeet bud,
Can't wait!

How long r u here bud?
2 Weeks Ary ... Back to DK on the 15th April :oops: Wish it was longer :cry:
Sean

Daily & Vent:
'14 SG FORD Wildtrak 4x4 - 'Stockish'
'94 OB VR6 - Stock
Ex:
'14 PW
GTI - 'Stock' - SOLD
'07 UG GTI - Modified - SOLD

"Lending my cars to you is a bit like lending your girlfriend to a porn star. Yes, you'll get her back but you just know she'll never be the same again... she'll always be wanting more"
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Post by Cupra_Ary » Mon Apr 02, 2007 4:15 pm

Chicken Licken wrote:
Polo_Ary wrote: Schweeeeet bud,
Can't wait!

How long r u here bud?
2 Weeks Ary ... Back to DK on the 15th April :oops: Wish it was longer :cry:
Lekker bru, we must meet up before you go!
Maybe all the guys can hook up and head to Tarlton on Thursday or something!
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Post by KJN » Tue Apr 03, 2007 12:39 pm

Nice technical tutorial with lots of pics! Looking forward to the dyno figures.

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Which front bumper is this? I was considering fitting the Sportech kit to my Polo but this front bumper looks very nice too.
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Post by mcgavin » Wed Apr 04, 2007 8:36 am

Car looks good!

That standard intercooler looks pretty weak. Does it even get any air from the front of the car? Ive been looking for mine and it seems pretty protected from any air flow.
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Post by Chicken Licken » Wed Apr 04, 2007 12:24 pm

mcgavin wrote:Car looks good!

That standard intercooler looks pretty weak. Does it even get any air from the front of the car? Ive been looking for mine and it seems pretty protected from any air flow.
That would be correct ... swaak airflow from the front to the OEM intercooler, RH was talking of cutting some fins into the plastic of the wheel arch to help with flow :x VW!!! Bad planning VW!!! :x
Sean

Daily & Vent:
'14 SG FORD Wildtrak 4x4 - 'Stockish'
'94 OB VR6 - Stock
Ex:
'14 PW
GTI - 'Stock' - SOLD
'07 UG GTI - Modified - SOLD

"Lending my cars to you is a bit like lending your girlfriend to a porn star. Yes, you'll get her back but you just know she'll never be the same again... she'll always be wanting more"
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Post by mcgavin » Wed Apr 04, 2007 1:02 pm

yeah i havent actually seen how much space is in front of the IC but i was thinking of puttig a bunch of fans in front of it to help with cooling?

EDITED: Oh my glory. Ive just spent 10 minutes trying to even spot the IC. There is no ways in hell that that IC even gets a bit of air - it might as well be in the boot for cooling. VW really thought that one through
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Post by Lambchop » Thu Apr 12, 2007 2:36 pm

Is there any updates to this thread???
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Post by mcgavin » Thu Apr 12, 2007 2:42 pm

checked the IC. found it behind the grill. doesnt look like it has awesome air flow but i was under the impression that the IC was for cooling the turbo, hence the concern but from another forum i posted i found out it was just for cooling air that the turbo uses, so i am not that concerned anymore.
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Post by RoadHaWg » Fri Apr 13, 2007 9:54 am

Lambchop wrote:Is there any updates to this thread???
:oops: :oops:
Stuart
2006 Jeep Wrangler "Sarge"
1966 Splitty.
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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Post by ryanrich » Fri Apr 13, 2007 10:31 am

Lambchop wrote:Is there any updates to this thread???
Yeah, I'm also quite curious to know the outcome after chipping etc...
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Post by Chicken Licken » Fri Apr 13, 2007 10:57 am

After a long 3 days of running around and much time spent etc there have been some developments with the setup.

Had a Run on Wednesday at KAR in Kempton

150 hp, 340 Nm atw

180 hp, 420 Nm atf


according to the A4 print out ... min bandwidth here at home to upload pic's etc of the scanned dyno sheet. :(

Late Wednesday afternoon a small nut on the impeller shaft let go and worked it's way back into the vanes of the intake. Thus shaft let go at it was offset and not balanced.

On the install something we missed ... :oops: ... as a result, i've contacted turbo exchange and there's a kit I can get and have the bushes etc changed out and vanes replaced at a small fee of around 350 bucks. So that will be my sidekick spare so to say :)

At the Moment, Stock SL Turbo, Stock Map, Custom intercooler still there, (nice for the good measure of cooling) 8)

It's been a challenging time to say the least but I've learnt a lot about diesels and how they work etc thanks to Morne :)

It was damn strong while it was mapped and running :D ... before the mishap :roll:

To spend the time and effort again at this stage would be like running the comrades twice in one day at this point. Maybe in the near future on a cloudy day I'll get the ball rolling again with custom pipes for the intercooler and maybe a VNT20 :twisted:

Roadhawg style 8)
Sean

Daily & Vent:
'14 SG FORD Wildtrak 4x4 - 'Stockish'
'94 OB VR6 - Stock
Ex:
'14 PW
GTI - 'Stock' - SOLD
'07 UG GTI - Modified - SOLD

"Lending my cars to you is a bit like lending your girlfriend to a porn star. Yes, you'll get her back but you just know she'll never be the same again... she'll always be wanting more"
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Post by EedubzShmeedubz » Fri Apr 13, 2007 12:38 pm

Chicken Licken wrote:Late Wednesday afternoon a small nut on the impeller shaft let go and worked it's way back into the vanes of the intake. Thus shaft let go at it was offset and not balanced.
thats not really true. the turbo failure has nothing to do with the shaft being off balance. the nut hitting the vains while they spinning at 15000rpm is wat caused the turbo to fail...

even if the shaft was some how miraculously perfectly balanced without the nut holding the compressor wheel in place, the turbo still wld b bust cos the vains wld b destroyed...
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Post by Chicken Licken » Fri Apr 13, 2007 3:19 pm

EedubzShmeedubz wrote: thats not really true. the turbo failure has nothing to do with the shaft being off balance. the nut hitting the vains while they spinning at 15000rpm is wat caused the turbo to fail...

even if the shaft was some how miraculously perfectly balanced without the nut holding the compressor wheel in place, the turbo still wld b bust cos the vains wld b destroyed...
Vanes = not one we could see was bust.

We found the nut at the bottom of the splash tray buy the sump between tho's plastic bubbles. So it just worked it's way off the impeller shaft and dropped to the tray.

The vanes are still intact on the shaft and the shaft is sitting at about 20 degree's and lose inside the housing.
Sean

Daily & Vent:
'14 SG FORD Wildtrak 4x4 - 'Stockish'
'94 OB VR6 - Stock
Ex:
'14 PW
GTI - 'Stock' - SOLD
'07 UG GTI - Modified - SOLD

"Lending my cars to you is a bit like lending your girlfriend to a porn star. Yes, you'll get her back but you just know she'll never be the same again... she'll always be wanting more"
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Post by EedubzShmeedubz » Fri Apr 13, 2007 3:27 pm

u said the nut that holds the compressor wheel to the shaft came loose...
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Post by g60 golf » Fri Apr 13, 2007 8:37 pm

The nut came off from the shaft at first glance it looked like it fell/sucked back in like on some of the vnt17 i have done.

But i asked chicken to check the thread lenght as it looks much longer
than it did.

The turbo snapped the shaft close to the impeller.

This is just speculation as we have not stripped the turbo.I think that the impeller wound itself deeper onto the shaft [longer thread] causeing it to break the shaft.

Damm it's not nice!!!!! :( :( :( :(
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Post by RoadHaWg » Mon Apr 16, 2007 9:54 am

Time to Squeeze a VNT-20 into a polo....
Stuart
2006 Jeep Wrangler "Sarge"
1966 Splitty.
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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Post by MrBee » Mon Aug 13, 2007 7:34 pm

Ouchy...

How'd she go just with the intercooler on and the stock turbo?

What was the outcome with the turbo? did you at least have that under some kind of warrantee?

This is the exact mod I had in mind for my Polo, only I was not gonna leave the OEM intercooler, and the brakes were gonna get some touching... new disks (312mm slotted) and bigger brembo calipers.

C
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Post by Chicken Licken » Mon Aug 13, 2007 7:47 pm

MrBee wrote:Ouchy...

How'd she go just with the intercooler on and the stock turbo?

What was the outcome with the turbo? did you at least have that under some kind of warrantee?

This is the exact mod I had in mind for my Polo, only I was not gonna leave the OEM intercooler, and the brakes were gonna get some touching... new disks (312mm slotted) and bigger brembo calipers.

C
It was great ... :D ... While that nut held out ... :)

Nice power ... there's a article that Eedubz wrote up in issue 4 of the upgrade in VDUB mag. See if you can get your hands on one. :) It's all in there ...

It's all stock now as it's for sale ... soon to be sold ... and the intercooler is spoken for incase you were wondering ;) :P
Sean

Daily & Vent:
'14 SG FORD Wildtrak 4x4 - 'Stockish'
'94 OB VR6 - Stock
Ex:
'14 PW
GTI - 'Stock' - SOLD
'07 UG GTI - Modified - SOLD

"Lending my cars to you is a bit like lending your girlfriend to a porn star. Yes, you'll get her back but you just know she'll never be the same again... she'll always be wanting more"
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