.: Polo TDI Sportline Turbo Upgrade and FMI Install :.
Posted: 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 ) 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
The turbo in question was a Garrett VNT1749VB - PD150 from the SEAT Cupra TDI. This would replace the OEM Garrett VNT1749V
The Parts
The Garrett VNT1749VB
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.
G60's tools for the job
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.
One of the first things to be removed was the airbox and the piped on the intake pipe to the turbo
The intake manifold was then removed
Roadhawg and G60 having a chat. Its amazing how much k@k guys can talk when they spend a day together working on cars. If the walls of that workshop could talk
The old turbo. The oil on the exhaust manifold is lube to loosen up the bolts
Some of the parts removed so far
Cool old tractor outside
Cool new tractor outside
One of many smoke breaks. I didnt feel left out tho
We needed a few odds and ends, and this is where we found them!!!
The old turbo being removed
The two turbos side by side. The new VB on the left, old V on the right
New VB on right, old V on left
G60 grining something
New turbo in place
My, how time flies...
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
The new intercooler
The front bumper comes off
The really tiny OE intercooler tucked away on the driver's side of the car
Chicken was obsessed with cleaning everything as it was exposed
The new FMI (Front Mount Intercooler) mock fitted to see what goes where and how we would run the boost piping
Some piping being fabricated
Next the front valance had to be removed to mount the FMI
Holes were drilled for the FMI mounts...
...and the mounts were attached
The FMI in place
A small section of the front valance had to be cut away to accomodate the FMI
Front valence goin back on
The "watcher"
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
Front bumper back on
The finished product
A very happy Chicken Licken
The end of a very fullfilling day
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
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
The parts were collected (thanx Tashen ) 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
The turbo in question was a Garrett VNT1749VB - PD150 from the SEAT Cupra TDI. This would replace the OEM Garrett VNT1749V
The Parts
The Garrett VNT1749VB
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.
G60's tools for the job
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.
One of the first things to be removed was the airbox and the piped on the intake pipe to the turbo
The intake manifold was then removed
Roadhawg and G60 having a chat. Its amazing how much k@k guys can talk when they spend a day together working on cars. If the walls of that workshop could talk
The old turbo. The oil on the exhaust manifold is lube to loosen up the bolts
Some of the parts removed so far
Cool old tractor outside
Cool new tractor outside
One of many smoke breaks. I didnt feel left out tho
We needed a few odds and ends, and this is where we found them!!!
The old turbo being removed
The two turbos side by side. The new VB on the left, old V on the right
New VB on right, old V on left
G60 grining something
New turbo in place
My, how time flies...
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
The new intercooler
The front bumper comes off
The really tiny OE intercooler tucked away on the driver's side of the car
Chicken was obsessed with cleaning everything as it was exposed
The new FMI (Front Mount Intercooler) mock fitted to see what goes where and how we would run the boost piping
Some piping being fabricated
Next the front valance had to be removed to mount the FMI
Holes were drilled for the FMI mounts...
...and the mounts were attached
The FMI in place
A small section of the front valance had to be cut away to accomodate the FMI
Front valence goin back on
The "watcher"
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
Front bumper back on
The finished product
A very happy Chicken Licken
The end of a very fullfilling day
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
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