The TwinCharge project;
This is the valve witch will provide the turbo of ext
ra air when the SC has run out;
Turbo inlet, valve and SC connection;
The Y-pipe had to be made of stainless steel because the PVC was melting!:
the connection between PVC and valve was'nt strong enough. So I bonded it together with some 2component glue:
WI connections to the air filter;
The motormounts where filled up with polyurethaan to make them stiffer;
The oilcooler went back on. This is the connection untherneath the oilfilter:
Mounting the oilcooler:
I used the original 4A-FE olicooler
The turbokit from XS-power;
Bought a GTI (NON-T-vis) plenium. Wich was not in his best schape but got it for 50 euro!:
Had to modify the SC outlet:
It has to run between the engine and the firewall.
And the inlet had to be shortned:
Had to modify the powersteering bracket (shifted 15 mm to the left):
An new bracket for the SC also had to be made:
Top mount;
The SC moved approx. 30mm down to accomodate the new plenium.
The rubbers for the axes where also shot and had to be replaced.
I also had to replace te origenal 4A-FE gearbox after 280.000 km's of service, of witch the last 10.000 km's with the GZE.
My exhaust was fitted with special V-band clamps:
And heat wrapped;
Piping for the new Front-Mount-Intercooler:
turbo to piping connection:
Exhaust manifold:
Now with screamer pipe!!:
Spraypainted the turbine housing to stop it rusting with high temp paint.(hope it wil withstand the temperatures!!)
New pipe for the GTI radiator:
My modifyde catch-can:
Oilpan connections for the turbo and oilcooler:
Megasquirt ready to go in the car;
The new inlet-air temp. sensor installed;
29-09-2007: At the moment I have some trouble with the wastegate opening at idle!
25-10-2007: Resolved the wastegate problem; the Wastegate bolting was coming loose and the spring is probably an 5-10Psi (0,35-0,7 bar) spring wich means the turbo isn't even near spooling when the wastegate is already opening. Fortunately my Megasquirt kit comes with a boostcontroller wich will keep the wastegate closed until I want it to open!
The car runs fine; when the SuperCharger kicks in the pressure goes from 0 to 0,6 bar in no time ad when it hits 0,9 bar@3000Rpm the turbo begins to spool and when it hits more then 1bar the feul-cut keeps the turbo from spooling.
At the moment I have little time to install the Megasquirt, but hope to find some time in the next couple of weeks.
KEEP U POSTED!!!!
Last updated on: 26-10-2007.
For questions mail to; rikdeckers@msn.com
