Superfox's 93 Wolfburg 2.0L Turbo Intercooler Last update May 24, 2006.

VW Fox 93 Wolfburg Edit. 2.0L Turbo Intercooler project.

� 3a Audi short block / 2.0L, (82.5mm x 92.8mm, 8V Audi 80 10.5-1CR)
� Scirocco's calipers / carriers. 10.1" vented / crossdrilled rotors.
� Rear discs, brake swap from MKII GTI,
� Autotech's Cam sprocket,
� ATP 8v turbo exhaust manifold
� Big Valve / polished Head, (40mm / 33mm),
� New wheel bearings, shocks, tie rods, lower ball joints, bushings, etc. (all around)
� Neuspeed lowering springs,
� Charcoal gray DP rims 195/50/R15,
� Autometer Air / fuel, oil pres., boost gauges
� Vortech Super-FMU 12:1 (Fuel Management Unit)
� Bosch 1:1 primal FPR
� Turbo XS Blow Off Valve
� Turbonetics external wastegate Mark Deltagate II
� Garrett To3 Super 60 turbo .60/.48,
� Starion FMIC. 17"(core)x8"x2.75",
� Zair's front grille, H4's & smoked cristal corner lamps
� G60 Front seats
� Volvo 940Turbo Injectors
� Digifant 1 w / Knock Sensor, chip, harness and all sensors
� Bat-on-Box / trunk w/ #0 wire
� walbro 255 in line fuel pump
� corrado G60 Throttle Body
� Stainless Steel / Mandrel bends / 2.25" IC pipes
� Braided Oil Lines w/ar fitings
� 3" mandrel, custom downpipe / Straight 3" exhaust
� DynoMax Ultra Flow� Round Muffler 3"

Before paint job

Side moldings gone. I've got the small ones but not sure if i'll use them when the paint job is ready.

H4 Head lights, smoked corner lights and front grille from VW Do Brazil.

Autometer boost and air/fuel mixture guages. On dash board Autometer oil pressure gauge.

Garrett T03 Unit .60/.48 "Super 60 turbo". Used on Chrysler 2.2L and 2.5L turbocharged engines.

Stainless Steel provides a surface 530% cooler than aluminum.
/ Mandrel bended pipes have a constant radius through the piping, allowing air flow w/o restrictions.

Fox II / rado's Throttle Body-The lower valve on the G-60 throttle body must be modified in order to keep it close. A blow off valve is installed to releive pressure to the atmosphere.

Turbonetics Deltagate Mark II external wastegate.

Boost control schematic

Bosch 1:1 primal fuel pressure regulator.

Oil sensor replaced with a "T" for oil gauge and turbine lubrication.

Digifant 1 harness

Digifant 1 / G-60 ECU schematic

POWER PLANT

2.0L Audi block code 3A(115@5400 122@3200) w / fox big valve head (8v) 40mm/33mm






Oil disgarge into crank case.



External wastegate
Custom made external waste gate flange. Drill and welded into the cast iron ATP exhaust manifold.




Starion FMIC. 17"(core)x8"x2.75" The right intercooler for foxes. Good for 29+psi and 300whp, fits perfect behind the grille, its widely available and relatively inexpensive compare with other front mounted intercoolers with similar dimensions.



[quote]
How hard is it to "slap" a turbo on a Fox? Are some Turbos easier than others? Personally i would think the turbo from a late 90's 1.8T passat would be easy, but I have also heard of people using turbos from Saabs and Volvos....any feedback would be appreciated.[/quote]

I've read the same question so many times that i feel the need to help my fellow foxers.
1st of all, it doesn't matter if u have a turbo from a Volvo, Saab, Ford, etc. what matters is that the turbocharger you are going to use fits ur needs. If u are turboing a car u should have a plan before u start the whole project. Before u buy any turbo u should know engine displacement and fueling system you're using. That includes injectors, pump, fuel regulator or regulators know as FMU (fuel management unit, ie. 1:1, 6:1, 10:1, 12:1) ecu, etc.
A turbocharger is a mechanical piece that's part of a whole new system of valves, pipes, sensors, etc. that are going to be attached to the engine. There are too many variables on turbo part sizes including compressor, fan blades (2), exhaust housing; this are known as stages. Turbo stages affect the performance of the vehicle as they'll produce lag, different top speed and the top amount of boost.
So if your turbo size goes along with the engine displacement then is just a matter of attaching the exhaust housing to your exhaust manifold; inlets and outlets to the pipes and so on. You should ask yourself not if the turbo is from an specific brand or model of car (Volvo, Saab, Ford, Audi, / KKK turbos, Garrett/Turbonetics, etc.) but to the size of the turbo.
Are some Turbos easier than others? yes, again bc of the turbo housing size and flanges. To3 flanges are very common (rectangular w/4 bolt pattern) ATP sells a cast iron exhaust manifold for 8v vdubs witch has a To3 pattern. If u have different flanges between turbo and manifold then u'll have to weld a flange to the turbo or the manifold to make them work. In my case i have the ATP exhaust manifold with a To3 garrett turbo and they fit perfectly but!, i had to weld a To3 flange to the exhaust manifold to work as a spacer. Happens that my turbo compressor is too big, so the additional flange pulls out the whole turbo from hitting on the intake manifold.

WOLFBURG INTERIOR

VW Corrado G60 front seats

BRAKES

Front
VW Scirocco calipers and carriers w/Zimmermman Cross drilled/vented 10.1" rotors




Rear 8.9" rotors

EXHAUST

DynoMax Ultra Flow� Round Muffler 3"

May 24, 2006........Body work in progress