9n3 Polo gti Forge TIP DIY

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9n3 Polo gti Forge TIP DIY

Postby RPGTI » 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 :hi: I got a new Forge TIP and a Forge throttle pipe (the pipe from the intercooler outlet to the throttle body) :hurray: .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. :twisted:

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.

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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)

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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.

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The pipe (think it is called a PD100) just pops off the front plastic inlet.

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Star screw releases it from the airbox.

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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.

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Here is where the bolt is.

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And the MAF sensor wire clip.

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The box loose.

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The box out.

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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)

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Then remove the feed pipe from the main steel boost pipe.

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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.

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Then remove the puck valve by undoing the clamp (I removed it completely so I had some more space to work).

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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.

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Then there is another pipe connected to the bottom of the TIP which also needs to be removed.

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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 :bang:

Image

Then it just requires you to reverse the steps. :hug:

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.

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And the final product.

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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. :driving:
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Re: 9n3 Polo gti Forge TIP DIY

Postby SemiColon » Fri Jul 13, 2012 8:01 am

Cool Thread!
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Re: 9n3 Polo gti Forge TIP DIY

Postby Neuk » Fri Jul 13, 2012 8:06 am

Nice write up, I see you are wearing gloves, is this to protect your painted nails?

:grin:
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Re: 9n3 Polo gti Forge TIP DIY

Postby RPGTI » Fri Jul 13, 2012 8:16 am

Neuk wrote:Nice write up, I see you are wearing gloves, is this to protect your painted nails?

:grin:

Of course haha
I just hate working around that little heat blanket on the boost pipe it's fibreglass and that crap stays in ur hands forever + they keep ur hands clean new age grease apie :lol:
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Re: 9n3 Polo gti Forge TIP DIY

Postby Neuk » Fri Jul 13, 2012 8:18 am

RPGTI wrote:
Neuk wrote:Nice write up, I see you are wearing gloves, is this to protect your painted nails?

:grin:

Of course haha
I just hate working around that little heat blanket on the boost pipe it's fibreglass and that crap stays in ur hands forever + they keep ur hands clean new age grease apie :lol:


Thats actually a good idea, once I have the necessary clamps I need to get my TIP in to the Vagon...
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Re: 9n3 Polo gti Forge TIP DIY

Postby Jueshen » Fri Jul 13, 2012 10:22 am

im using mk4tip also lol want to change to proper polo one..
but the thing is im making awesome power so dont think changing it will let me make more.
the only pipe that got a bit of a curve is the one to my forge dv...
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Re: 9n3 Polo gti Forge TIP DIY

Postby Smok3X » Fri Jul 13, 2012 10:40 am

Brilliant thread! Thank you! and well done! :hurray:
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Re: 9n3 Polo gti Forge TIP DIY

Postby jk » Fri Jul 13, 2012 10:50 am

Well done!!
How much does the throttle pipe go for?
Mine is very soft, im sure it collapses easily with boost.

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Re: 9n3 Polo gti Forge TIP DIY

Postby Stompie » Fri Jul 13, 2012 10:52 am

jk wrote:Well done!!
How much does the throttle pipe go for?
Mine is very soft, im sure it collapses easily with boost.


if im not mistaken, i paid R1650 for mine...but think it was on special that time?
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Re: 9n3 Polo gti Forge TIP DIY

Postby jk » Fri Jul 13, 2012 10:57 am

PoloGTIman wrote:
jk wrote:Well done!!
How much does the throttle pipe go for?
Mine is very soft, im sure it collapses easily with boost.


if im not mistaken, i paid R1650 for mine...but think it was on special that time?


The TIP or Throttle pipe?
Thats not fair, the Throttle pipe is just solid pipe, what a rip off.

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Re: 9n3 Polo gti Forge TIP DIY

Postby Stompie » Fri Jul 13, 2012 11:02 am

this is for the TIP, im not sure on pricing for the TB pipe, dont have it...
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Re: 9n3 Polo gti Forge TIP DIY

Postby SemiColon » Fri Jul 13, 2012 11:17 am

TP is around R600
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Re: 9n3 Polo gti Forge TIP DIY

Postby Stompie » Fri Jul 13, 2012 11:18 am

SemiColon wrote:TP is around R600


where? and probably not forge?
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Re: 9n3 Polo gti Forge TIP DIY

Postby MeanTdi » Fri Jul 13, 2012 11:24 am

Fantastic write up!
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Re: 9n3 Polo gti Forge TIP DIY

Postby Smok3X » Fri Jul 13, 2012 11:30 am

jk wrote:Well done!!
How much does the throttle pipe go for?
Mine is very soft, im sure it collapses easily with boost.


I am quite sure that the Throttle pipe wont ever collapse under boost... Thats impossible with a positive boost pressure! Someone explain if I am wrong please?

Lets think about this, if you blow into a super soft straw... blow really hard... will it ever collapse?

No never, if you block it off at one end, it could blow up like a balloon and pop, but not collapse.

It will collapse under suction, thats a negative boost pressure in a closed system. Block a straw at one end and suck... watch the collapse!

The throttle pipe could collapse "out of boost" IF the intake side was blocked somehow or severly restricted, as that is when you have a negative pressure in the manifold...and even then the engine would stall lol.

The "collapse" you refer to can only happin in the INTAKE pipe, thats the TIP peole refer to, especially if you have a blocked or dirty air filter in the stock airbox and are running high boost... thats when the Turbo is sucking against a restriction...and you MAY have a TIP collapse... otherwise I dont see a throttle pipe collapsing.
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Re: 9n3 Polo gti Forge TIP DIY

Postby SemiColon » Fri Jul 13, 2012 11:40 am

PoloGTIman wrote:
SemiColon wrote:TP is around R600


where? and probably not forge?


At Revo, i cant remember the exact Price, but it was around the R600-R700 mark.
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Re: 9n3 Polo gti Forge TIP DIY

Postby Stompie » Fri Jul 13, 2012 11:49 am

Smok3X wrote:
jk wrote:Well done!!
How much does the throttle pipe go for?
Mine is very soft, im sure it collapses easily with boost.


I am quite sure that the Throttle pipe wont ever collapse under boost... Thats impossible with a positive boost pressure! Someone explain if I am wrong please?

Lets think about this, if you blow into a super soft straw... blow really hard... will it ever collapse?

No never, if you block it off at one end, it could blow up like a balloon and pop, but not collapse.

It will collapse under suction, thats a negative boost pressure in a closed system. Block a straw at one end and suck... watch the collapse!

The throttle pipe could collapse "out of boost" IF the intake side was blocked somehow or severly restricted, as that is when you have a negative pressure in the manifold...and even then the engine would stall lol.

The "collapse" you refer to can only happin in the INTAKE pipe, thats the TIP peole refer to, especially if you have a blocked or dirty air filter in the stock airbox and are running high boost... thats when the Turbo is sucking against a restriction...and you MAY have a TIP collapse... otherwise I dont see a throttle pipe collapsing.


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Re: 9n3 Polo gti Forge TIP DIY

Postby RPGTI » Fri Jul 13, 2012 12:25 pm

The trottle pipe cost me R700 and the TIP R1675 from Yosh @ unitronic.
The trottle pipe wont collapse as thye have mentioned above but the TIP will for example the oem pipe is half rubber half metal the metal half is narrow and restrictive and the rubber part is thin and its easy to squash it.

The throttle pipe will just burst after time and it gets hot alot quicker from the engine bay heat as apposed to the silicone forge one.
Also if you see in the pic with the polo and golf tip next to each other the polo one is actually bigger in most parts less of a bottle neck I guess I highly doubt there will be power changes from both pipes if anything the polo one feels stronger.
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Re: 9n3 Polo gti Forge TIP DIY

Postby SemiColon » Fri Jul 13, 2012 12:36 pm

RPGTI wrote:The trottle pipe cost me R700 and the TIP R1675 from Yosh @ unitronic.
The trottle pipe wont collapse as thye have mentioned above but the TIP will for example the oem pipe is half rubber half metal the metal half is narrow and restrictive and the rubber part is thin and its easy to squash it.

The throttle pipe will just burst after time and it gets hot alot quicker from the engine bay heat as apposed to the silicone forge one.
Also if you see in the pic with the polo and golf tip next to each other the polo one is actually bigger in most parts less of a bottle neck I guess I highly doubt there will be power changes from both pipes if anything the polo one feels stronger.


Tests conducted on the Forge TIP on the Polo showed an increase of 10-15g/s flow vs. the Stock TIP.
-i just wish they also made TIP's that you can BOLT on to the turbo as i have lost faith in clamping it to the turbo....because mine popped off
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Re: 9n3 Polo gti Forge TIP DIY

Postby Stompie » Fri Jul 13, 2012 12:39 pm

when i had mine fitted at Gtek-lee, he said he puts a small amount of dish wash liquid to slip it on and then when it gets hot also acts a glue...maybe just take it to him and let him fit it, he charged me R200 to fit...

and i havent had any problems with mine coming off....
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Re: 9n3 Polo gti Forge TIP DIY

Postby RPGTI » Fri Jul 13, 2012 1:36 pm

Depends on the clamp you could use a t bolt clamp if you want or just find a decent clamp and instead of tightening it with a flat or star use a socket then they will be very tight.In theory they shouldnt pop of as they getting sucked on the golf one i had on the clamp wasnt even that tight cause the piece at the bottom was a little short and every time i tightend it squashed the pipe off.
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Re: 9n3 Polo gti Forge TIP DIY

Postby SemiColon » Fri Jul 13, 2012 1:46 pm

RPGTI wrote:Depends on the clamp you could use a t bolt clamp if you want or just find a decent clamp and instead of tightening it with a flat or star use a socket then they will be very tight.In theory they shouldnt pop of as they getting sucked on the golf one i had on the clamp wasnt even that tight cause the piece at the bottom was a little short and every time i tightend it squashed the pipe off.


Yes, i'm also at a los at to how mine came off, it was tightend epicly and the edge of the TIP was longer than the previous Forge ons so there was enough space to clamp it in...
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Re: 9n3 Polo gti Forge TIP DIY

Postby jk » Fri Jul 13, 2012 1:59 pm

Smok3X wrote:
jk wrote:Well done!!
How much does the throttle pipe go for?
Mine is very soft, im sure it collapses easily with boost.


I am quite sure that the Throttle pipe wont ever collapse under boost... Thats impossible with a positive boost pressure! Someone explain if I am wrong please?

Lets think about this, if you blow into a super soft straw... blow really hard... will it ever collapse?

No never, if you block it off at one end, it could blow up like a balloon and pop, but not collapse.

It will collapse under suction, thats a negative boost pressure in a closed system. Block a straw at one end and suck... watch the collapse!

The throttle pipe could collapse "out of boost" IF the intake side was blocked somehow or severly restricted, as that is when you have a negative pressure in the manifold...and even then the engine would stall lol.

The "collapse" you refer to can only happin in the INTAKE pipe, thats the TIP peole refer to, especially if you have a blocked or dirty air filter in the stock airbox and are running high boost... thats when the Turbo is sucking against a restriction...and you MAY have a TIP collapse... otherwise I dont see a throttle pipe collapsing.


Collapse/Expand - same same, my TP gets very hot and becomes soft, if you squeeze it it feels very weak.

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Re: 9n3 Polo gti Forge TIP DIY

Postby Smok3X » Fri Jul 13, 2012 2:02 pm

What kind of sound does the 007DV make? if any?
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Re: 9n3 Polo gti Forge TIP DIY

Postby Stompie » Fri Jul 13, 2012 2:03 pm

Smok3X wrote:What kind of sound does the 007DV make? if any?


with a induction....it makes a loud whooooooosssshhhh sound
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