9n3 Polo gti Forge TIP DIY
Posted: Thu Jul 12, 2012 9:16 pm
So I had to change out my Turbo inlet pipe or TIP this past weekend as I had been using a Golf 4 GTI TIP from the get go (dont ask me how but with extended pipes and some squashing it does fit). So thanks to Yosh I got a new Forge TIP and a Forge throttle pipe (the pipe from the intercooler outlet to the throttle body) .The throttle pipe is alot firmer then the stock one which you are able to squash side to side but the forge one you cant not sure on major benifits but will definatly help.
So firstly I had to remove the filter and the 90 degree silicone bend by loosening the clamp holding it to the mass airflow or MAF sensor.
Second I had to remove the MAF sensor itself als held on with a clamp,it also need to be unplugged.(make sure the key is out of the ignition it maybe throw a error if it is)
Then to get easier access I removed the air inlet from the front grille (think it is a PD 100 pipe) which was 2 hex screws.
The pipe (think it is called a PD100) just pops off the front plastic inlet.
Star screw releases it from the airbox.
Now to remove the airbox,It is held in place with 1x10mm bolts (it's fairly long) and then rubber seats that hold it in place and stop it from knocking on eveyrthing 1 round one by the batter which you just pull towards yourself and one at the back which fits over a metal pine both just pull off (make sure you seat them properly before you put the box back).Unclip the MAF sensor wire (remember to clip it back) and the box should be free.
Here is where the bolt is.
And the MAF sensor wire clip.
The box loose.
The box out.
Then comes the n75 valve firstly unclip the connection and loosen the lower clamp (stock pipes will have spring type clamps).(remember which pipe went where if its wrong it wont control your wastegate)
Then remove the feed pipe from the main steel boost pipe.
Then the feed pipe to the wastegate I use vise grips the ones you can lock in place they tend to hold the clip open for a long time to be able to move it around easier.
Then remove the puck valve by undoing the clamp (I removed it completely so I had some more space to work).
Then comes removing the dumpvalve from the TIP once again undoing the clamp releases it.With the oem pipe from the boost pipe to the dumpvalve you need to cut and extend it I ended up buying some water line hose and using that as apposed to the oem pipe + that hose had split abit the water hose holds up to heat well but the silicone ones will work much better I recon.
Then there is another pipe connected to the bottom of the TIP which also needs to be removed.
Then comes climbing under the car to get the TIP off.On the oem pipe the bottom half of the pipe is metal which has a 10mm bolt holding it to the turbo inlet, undo that and the TIP should be free or like in my case I had a clamp holding the TIP (aftermarket) to the turbo which you get best access to from under the car.
As you can see the Golf TIP looks alot different from the Polo TIP make sure you buy the right one first time
Then it just requires you to reverse the steps.
Some tips:
> A good quality clamp for the TIP where it joins the turbo it best so you only have to do it once.
> Wear glasses if you going under the car enough sand in the eye from that.
> The spring type clamps lose their clamping abillity after being heated and cooled and reheated so just replace them.
> Make sure all the clamps are tight ecspecially the dumpvalve.
The Throttle pipe is a straight fit loosen the top and bottom clamps remove the pipe and replace it with the Forge pipe and tightend the clamps up.
And the final product.
The job took me around a hour or 2 or 3 but cost me nothing to fit other then the pipes.
The car feels more responsive there would be some more performance I assume as it's less restrictive now
and ofcourse the sound.
So firstly I had to remove the filter and the 90 degree silicone bend by loosening the clamp holding it to the mass airflow or MAF sensor.
Second I had to remove the MAF sensor itself als held on with a clamp,it also need to be unplugged.(make sure the key is out of the ignition it maybe throw a error if it is)
Then to get easier access I removed the air inlet from the front grille (think it is a PD 100 pipe) which was 2 hex screws.
The pipe (think it is called a PD100) just pops off the front plastic inlet.
Star screw releases it from the airbox.
Now to remove the airbox,It is held in place with 1x10mm bolts (it's fairly long) and then rubber seats that hold it in place and stop it from knocking on eveyrthing 1 round one by the batter which you just pull towards yourself and one at the back which fits over a metal pine both just pull off (make sure you seat them properly before you put the box back).Unclip the MAF sensor wire (remember to clip it back) and the box should be free.
Here is where the bolt is.
And the MAF sensor wire clip.
The box loose.
The box out.
Then comes the n75 valve firstly unclip the connection and loosen the lower clamp (stock pipes will have spring type clamps).(remember which pipe went where if its wrong it wont control your wastegate)
Then remove the feed pipe from the main steel boost pipe.
Then the feed pipe to the wastegate I use vise grips the ones you can lock in place they tend to hold the clip open for a long time to be able to move it around easier.
Then remove the puck valve by undoing the clamp (I removed it completely so I had some more space to work).
Then comes removing the dumpvalve from the TIP once again undoing the clamp releases it.With the oem pipe from the boost pipe to the dumpvalve you need to cut and extend it I ended up buying some water line hose and using that as apposed to the oem pipe + that hose had split abit the water hose holds up to heat well but the silicone ones will work much better I recon.
Then there is another pipe connected to the bottom of the TIP which also needs to be removed.
Then comes climbing under the car to get the TIP off.On the oem pipe the bottom half of the pipe is metal which has a 10mm bolt holding it to the turbo inlet, undo that and the TIP should be free or like in my case I had a clamp holding the TIP (aftermarket) to the turbo which you get best access to from under the car.
As you can see the Golf TIP looks alot different from the Polo TIP make sure you buy the right one first time
Then it just requires you to reverse the steps.
Some tips:
> A good quality clamp for the TIP where it joins the turbo it best so you only have to do it once.
> Wear glasses if you going under the car enough sand in the eye from that.
> The spring type clamps lose their clamping abillity after being heated and cooled and reheated so just replace them.
> Make sure all the clamps are tight ecspecially the dumpvalve.
The Throttle pipe is a straight fit loosen the top and bottom clamps remove the pipe and replace it with the Forge pipe and tightend the clamps up.
And the final product.
The job took me around a hour or 2 or 3 but cost me nothing to fit other then the pipes.
The car feels more responsive there would be some more performance I assume as it's less restrictive now
and ofcourse the sound.