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If you want your TDI to be quick...

Currently reading:
If you want your TDI to be quick...

Definately becoming an interesting Read.

First off - I am from "NEAR" Liverpool originally, however now living in Nottingham. (Let's not get confused between a scouser and a woolyback now ;))

http://en.wikipedia.org/wiki/Woolyback - I'm from Widnes. :)

- I'm around 75 miles from Silverstone, so not that far in terms of driving distance. Just over an hour or so.

Dan, thank you for your kind words regarding the Bora. :)

John... The new intercooler and pipework, I'm pretty desperate for, since I could damage my Turbo if it keeps on blowing off the EGR valve.
And of course, there's no way I can have a NOS system installed without some adequate cooling :)

I've a requestion regarding NOS'ing a TDI - Am I correct in saying that the limiting factor is the flow through the Turbocharger that gets rid of exhaust gasses? Or am I talking a load of cobswallop?

Please tell me more, John. :)
 
A nitrous system will aid cooling quite dramatically as you are jetting pressurised nitrous oxide through your system. It is seriously f'ing cold.

Dan
 
Regardless, is what I'm saying.. Where my EGR valve joins my silicon piping - it's not the best of connections shall we say. It works, but periodically blows off. Bloody annoying too.
 
Buy a samco hose from DemonTweeks. They have all sorts of angled hoses etc.
 
re

i dont thin kanyone could weld samco hose? lol or i guess thats a reply to an earlier comment!

find any custom exhaust place, they should be abel to make you up a stainless steel pipe however u want it!
 
I know Samco hoses are silicon. Dummy :)

It's more to do with the fact that the OEM VW pipe is supposed to fit inside the EGR valve with an O-ring, however, the OEM application is seriously dire, and too much Turbo Pressure (>2Bar) just completely shears off the dimples inside the OEM VW pipe, thus causing boost leakage, hence wanting some custom kit like the one shown in the picture above.

As I've already said; I've got a custom silicon kit, that goes over the EGR valve, instead of inside it. Not great, but it works, 99% of the time...
 
Yeah sorry it was to an earlier post. There was a guy on ebay who made custom pipes. If i ever come across it i'll give you a shout on here.
 
I found a company that will fit a new Intercooler, plus all pipework, for the fitted price of £870.

That's a hefty wedge to part with - before any real modifications start. Is there anything I should ask about? LOL.
 
***Message Deleted at original posters request. Please stay on topic***
 
***Message Deleted at original posters request. Please stay on topic***
 
OK - So back on topic.

I've got my Intercooler (Standard PD150 one) and pipework ordered.

The Standard PD150 intercooler is twice the size in every dimension compared to the PD130 intercooler, and is also front-mounted. The PD130 is smaller so is side-mounted and fits within the wheel-arch.

The only other difference between the 130 and 150 is the chamber inside the Turbo, hence when you remap both, they come out relatively similar. :) (about 10BHP difference top end, before the injectors hit their threshold, they're identical, as is the camshafts, pistons, etc)
 
i'm not familiar with your problem Ian, but how is the hose currently held on? does the hose go OVER or inside? ie, is it a jubilee type clip holding it on?
I could be going in completely the wrong direction, but would something like this help:
http://www.powerengineering.co.uk/mikalor/faq/faq.htm
turbo.jpg

exhaust.jpg

clamp.jpg

clamp4.jpg


much cheaper i'd have thought than custom SS pipework. Its shown at the top their being used on turbo hoses. Its probably inferior to welded on SS pipework mind you, but for the price, worth a trial?
 
oh, and this thread is defo getting interesting Ian, thanks for starting it.(it started interesting) so one for me to bookmark for the future i think...

Buzz
The champion of the Bravo 1.4 & now ex owner of a Bravo 1.8

Member Page
 
re

from what i've read the oe pipe goes inside, but Ian has some samco that goes outside now? I agree i hate jubilee clips, maybe i'm just heavy handed but i always seem to overtighten them and then you can't tighten them anymore. we sell the clips like that at work if i still had my fiat on the road i'd be swapping them out slowly.


I believe smee also had problems with pipes comiong off his intercooler and was advised to swap for these hose clips

If you can use oe fmic and pipework then 870 is a lot of money for a custom one? someone must be able to copy the oe one? i know a lot of oem intercoolers have plastic end tanks? and they can start leaking?
 
Ok update -

Originally the EGR valve is a peice of equipment that bolts onto the inlet manifold on all TDI's - This just basically recirculates dirty air.
When on full throttle, the EGR is fully closed, meaning that no air recirculates the engine, however at idle, it's completely open - meaning the engine is effectively burning dirty air.

The OEM VW pipe sits inside of this EGR valve, and has two dimples eitherside of the outer pipe - When fitted inside of the EGR valve, an O-Clip goes over the top of the EGR valve and the dimples on the outside of the OEM pipe and wedged into place.
However, when great pressures occur, these dimples simply get sheared off. Not good.

Solution:

Contact Allard and get yourself a pipe kit. This includes a custom-built inlet manifold which completely does away with the EGR valve.
Afterall, the only reason it's in place is for emissions at idle. Your diesel will STILL PASS the MOT without the EGR valve. They said on some cars with the EGR removed, it leaves a light on the dash, but not with the Volkswagen-Audi Group.
And of course, the custom pipework from Allard is custom made to fit the custom inlet manifold.

This completely does away with the issue of my samco hosing not being able to grip the cast EGR valve properly.

HOWEVER, apparently VW took back the original O-clip and OEM pipe as this is a common fault and redesigned it, and now instead of the O-clips being silver, they're green, and obviously much stronger.

I'm still not shedding out £60 to find out whether an OEM pipe works or not, when I can get a whole Allard kit (apart from Intercooler) for £270. This includes the custom inlet manifold. NICE :)

The kit also fits the Standard PD150 intercooler (front mounted), hence the reason for changing my PD130 Intercooler that's side-mounted, for a PD150 standard Intercooler that's front-mounted. I got a second-hand one for £50.

Allard also say that their uprated intercooler fits into exactly the same place as the OEM PD150 Intercooler, it's just twice as deep - nothing more.
 
sorry been away.

ian EVERYTHING u need from pipe work upgrade to a full on phase 4 tuning can be done at ALLARDS

http://www.allardmotorcompany.com/allard.asp

i know loads of people that have been here.

one of them even went back with a new car the a3 i telling u about with propane injection and nos.

they sell get them to fit an intercooler and i think u get the EGR replacement pipe for peanuts

Smee

smeetag2.jpg
 
allards intercoolers are smaller than the ones i have seen. unless my seat one is differnt

Smee

smeetag2.jpg
 
Smee, you're 10 steps behind me.

I've already ordered the pipework and the bypass inlet manifold from Allards. Read above :)
 
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