B6 Turbo Build, Questions and Updates

[MmmBoost]

You most likely won't need a fuel pump for this setup.

and if you really wanted to you could just run the GTRS off of the wastegate spring. Keep the N75 hooded up electrically but remove it from the system. The only risk with this is that you may get an underboost code if the ECU is requesting 20 PSI and you're only getting 13 or 14

[EBG 18T]

I was told by the turbo supplier that running it on the Uni S2 file would be fine for the time being. The turbo will just supply the boost requested by the file right? I dont run a MBC, so I won't be cranking the boost up anything. But the major reason for not doing it right away is cost honestly. I don't have the funds ready to reflash at the moment. I still hope to get this all done in the next couple months. It couldn't hurt to let the turbo break-in for a month at low boost anyhow. Plus its cold as balls and I don't want it over stressed.

It's you car not mine...

[EErie B6]

If it is not too late, I'd look to the REVO 550cc file instead of Unitronic.

[MmmBoost]

He's already got Uni Stage2.....so all he has to do is pay for the upgrade vs. buying an all out Stage 3 from a new tuner

[EErie B6]

after he enjoys his new found lack of driveability, he will wish he had.

[Roadblock]

wow thats all i have too say thanks for the info guys please keep posting more so when my time comes around i know what needs to be done. lol

[KFizz]

To the best of my knowledge there is no Revo dealer where I live. And I'm not sure I believe running a Uni BT file and not a revo one is going to result in a lack of driveability.

Anyhow, you guys can be condecending if you want. I know this isn't going down in an ideal manner. My turbo ate shit, It requires a replacement, Now. I could have replaced it with another K03, that just seems stupid and it's not even that much cheaper. K04 seems almost obsolete these days. The remaining options were basicaly Frankenturbo and GTRS. I've committed to the GTRS at this point. I'm trying to make the most of a bad situation, with limited resourses. I will get this project completed sucessfully. It's just going to happen on a bit of an awkward timeline, with a few temporary sacrifices along the way. Please just accept this as the reality of my situation. If nothing else it can be something entertaining for you guys to watch. Me struggling with my turbo build. This is the way it's gotta happen.

[EErie B6]

I am not trying to crush your dreams or be condescending. I have and run the Uni630 BT tune and it sucks. That's first hand experience... If my car was a daily, I'd have set it on fire by now... I have heard similar reports from others.

I have not heard the same complaints from the REVO users & that least me to believe the REVO file is a little more refined.

That is all. Do what you feel is right.

[M-Hood]

Damn I'm becoming worried now. I was under the impression the file would still keep the turbo in check, mistakenly aparently. What if I did run a MBC and just kept the boost down? Would this eliminate, or at least lessen the chances of running lean? I suppose I could just unplug the N75 as well, if it came to that. Until I could get the file and injectors.

Well it's good this is comming up now. I want to make sure I'm as ready as possible when this thing arrives. Alright well I guess I'll try to accelerate the injectors and reflash then. Put the coilpacks on hold. I was thinking the feul pump was more of a requirement. If not then I'll backburner that aswell.

Alright thanks guys. I'll proceed on a slightly different route then.

Even if you bypassed the N75 valve the turbo would still produce 1 bar of boost seeing that is what the WG spring is set for.

[KFizz]

Even if you bypassed the N75 valve the turbo would still produce 1 bar of boost seeing that is what the WG spring is set for.

Okay good to know. This also explains why my turbo is currently (ko3) still building boost, even with the N75 disconnected.

I did some more reading last night. Trying to refine my strategy a bit. Discovered a few things. All of the Uni BT software requires a TT225 MAF housing. No big deal really except I run a carbonio intake. I guess this can be reamed to a larger opening. It's been a while since I've really looked at the thing so I'm not too sure hard that will be. It seems it's been done a number of times by other members. Is this the only solution here?

The GTRS kit I ordered has a fitting to reduce the inlet down to the size of the factory TIP. It looks to be removable. If I want to run a larger 3" inlet, do I just need to purchase another fitting for the front of the turbo? I havn't been able to find this part anywhere.

Lastly. Who all manufacturers a TIP that will connect a 2.75" MAF housing (stock location) to a 3" turbo inlet? I see that 034 has one, I havn't been able to find any others. I have no problems with a 034 product, just wondering if there are options.

Thanks

[M-Hood]

Okay good to know. This also explains why my turbo is currently (ko3) still building boost, even with the N75 disconnected.

I did some more reading last night. Trying to refine my strategy a bit. Discovered a few things. All of the Uni BT software requires a TT225 MAF housing. No big deal really except I run a carbonio intake. I guess this can be reamed to a larger opening. It's been a while since I've really looked at the thing so I'm not too sure hard that will be. It seems it's been done a number of times by other members. Is this the only solution here?

The GTRS kit I ordered has a fitting to reduce the inlet down to the size of the factory TIP. It looks to be removable. If I want to run a larger 3" inlet, do I just need to purchase another fitting for the front of the turbo? I havn't been able to find this part anywhere.

Lastly. Who all manufacturers a TIP that will connect a 2.75" MAF housing (stock location) to a 3" turbo inlet? I see that 034 has one, I havn't been able to find any others. I have no problems with a 034 product, just wondering if there are options.

Thanks

3" inlet for the Elim? The larger inlet for that turbo is 2.5". The MAF end of the hose needs to be 3" for the larger TT225 MAF housing which is 3" OD and 2.75" ID.

This is the 034 hose you want and the 2.5" inlet option listed on that page.
http://www.034motorsport.com/engine-...f-p-18594.html

Neuspeed also offers a hose for the 2.5" turbo inlet adapter, but it is 2.75" on the MAF end for the stock 2.75" OD MAF housing.

[KFizz]

Alright well I'll add that to the list then. If anyone happens to have one of these for sale let me know.

[KFizz]

So all of the local Unitronic dealers are looking for $650 to upgrade to the BT file. Which is $890 new. So they're giving me a $240 credit for the $650 worth of software I already purchased. I'm not too happy about this. The REVO software is now much more of a posibillity.

[M-Hood]

So all of the local Unitronic dealers are looking for $650 to upgrade to the BT file. Which is $890 new. So they're giving me a $240 credit for the $650 worth of software I already purchased. I'm not too happy about this. The REVO software is now much more of a posibillity.

This is because the ECU has to be sent to Unitronics to have the BT tune installed directly into the ECU, it cant be done at the dealers.

[MmmBoost]

Just a heads-up the local Revo dealer is Norden VW.

The 550cc injectors are WORLDS better than the 630's anyway.

[vinny.dtw]

Just a heads-up the local Revo dealer is Norden VW.

The 550cc injectors are WORLDS better than the 630's anyway.

Agreed.

I've had the Revo file for years... It was all turn key and go. No idle issues, no lean codes, no rich codes, no CEL's, traction control works, cruise works. There was nothing bad about that file for the GTRS Elim.

[EErie B6]

So all of the local Unitronic dealers are looking for $650 to upgrade to the BT file. Which is $890 new. So they're giving me a $240 credit for the $650 worth of software I already purchased. I'm not too happy about this. The REVO software is now much more of a posibillity.

I think it would be a wise decision in the long run.

Just a heads-up the local Revo dealer is Norden VW.

The 550cc injectors are WORLDS better than the 630's anyway.

This.

I've had the Revo file for years... It was all turn key and go. No idle issues, no lean codes, no rich codes, no CEL's, traction control works, cruise works. There was nothing bad about that file for the GTRS Elim.

more supporting evidence from someone who has it.

[KFizz]

Yea I never really doubted the possibility that the Revo software might be better. I'm just really suprised Uni is hosing everyone on the cost of the upgrade. I went with them in the first place, partly to support a Canadian company. Now I'm not so sure...

[M-Hood]

Just a heads-up the local Revo dealer is Norden VW.

The 550cc injectors are WORLDS better than the 630's anyway.

Are you comparing Bosch to Bosch or Bosch 550cc vs some other brand 630cc injectors?

The Bosch EV14's are by far the best injectors, even the large EV14's have a better droplet then the brand 630cc injectors.

[MmmBoost]

I was comparing the injectors used on the Revo 550 software (genesis/bosch) vs. the Siemens Deka 630's used in the Unitronic.

The Siemens 630's are useless pieces of garbage. This is based on trying to tune them, as well as how my car ran on them. Installed Genesis 550's and barely made any adjustments other than my injectors constant and latency map......and the engine ran like a completely different animal. The idle was MUCH more smooth and the power delivery was buttery as well.

[diagnosticator]

To simply put it...your turbo supplier is a retard.

Can you do it? Possibly. Should you do it? Probably not. If your process is only a few days, then I'd say you are more or so Ok...few weeks of daily driving? Not such a good idea.

In laymen terms your tune is requesting for an xx amount of air at xx psi. Your GTRS will provide A LOT more air at xx psi then your k03 will. More air + not enough injectors for fuel to compensate for the air = running lean. Running lean for too long = engine kaboom.

But like I said...it's a recommendation. Good luck buddy, hope that helps.

The GTRS flows the same mass air as the KO3 does at the same engine load point, same boost pressure. So if the file calls for 20 psi boost, the Mass air flow at 20 psi boost is the same for both turbos. The GTRS won't be running as fast as the K-03/04 at equivalent boost and mass air flow rates.

[KFizz]

So I just got off the phone with a Revo dealer in Calgary. The Edmonton dealer is aparently out of comission at the moment. Revo 550 file with a free SPS3 for $599. This is actually $50 less than the "upgrade" to the Uni BT file. They said I can courier my ECU down and could very likely have it back the same day, if not the next morning. Also recommended I pick up another ECU and sell my current one. re-coup some of my money.

They also deal Eurodyne. This is more money, and I think a bit over my head. An option though.

[viceprp]

So I just got off the phone with a Revo dealer in Calgary. The Edmonton dealer is aparently out of comission at the moment. Revo 550 file with a free SPS3 for $599. This is actually $50 less than the "upgrade" to the Uni BT file. They said I can courier my ECU down and could very likely have it back the same day, if not the next morning. Also recommended I pick up another ECU and sell my current one. re-coup some of my money.

They also deal Eurodyne. This is more money, and I think a bit over my head. An option though.

ME7 > Revo. It would be well worth the money.

[MmmBoost]

ME7 > Revo. It would be well worth the money.

Not everyone has the interest, patience, or need to go that route.

GTRS is a pretty off-the shelf file that has been revised a number of times.

[KFizz]

Alright a quick Update. Turbo came across the border into Vancouver today. I've asked them to overnight ship it to my office, in Edmonton. Should be here tomorrow morning. So this weekend, finally, I'll be putting this damn thing in. Very excited.

[KFizz]

Yea as far as ME7 goes. It's basically just as Chris said. I have no doubts it's better software, I just cant really spend the time tuning this thing myself at the moment. This is my daily driver, so I just need it to work. So it'll likely be revo at this point.

[KFizz]

I have a slight issue. Turbo arrived, but the 3 bolts that connect the turbo to the exhaust manifold are missing. Does anyone know if I can use the stock bolts?

[Matt Devo]

I have a slight issue. Turbo arrived, but the 3 bolts that connect the turbo to the exhaust manifold are missing. Does anyone know if I can use the stock bolts?

personally, I would (and did) replace all the studs, bolts, and gaskets. It's relatively cheap compared to the price of the turbo, and will make installation much easier. I'd also recommend getting different nuts for the turbo->cat studs, since the stock 17mm ones are quite difficult to install/remove. ATP offers 14mm nuts IIRC.

[KFizz]

Yea this is the ATP eliminator kit. It has everything but the manifold bolts. Must have been missed. They are the same size though?

[Matt Devo]

Yea this is the ATP eliminator kit. It has everything but the manifold bolts. Must have been missed. They are the same size though?

yes, same as stock. I picked up the ECS K03/K04 install kit and used that.

[KFizz]

So one of these manifold bolts is being a real bitch. The one closest to the head. There is no clearance for a socket. Wrench isn't working well. What are people doing here? I'm about to grind a socket down.

[Matt Devo]

So one of these manifold bolts is being a real bitch. The one closest to the head. There is no clearance for a socket. Wrench isn't working well. What are people doing here? I'm about to grind a socket down.

I used a 17mm 3/8" socket + swivel joint + 6" extension to break and for final tightening, otherwise a 17mm wrench 1/8 turn at a time

[KFizz]

Yea none of my swivels were fitting, ended up cutting down one of my 17mm sockets with an angle grinder. Worked like a charm actually I'll be keeping the socket for the future.

Turbo is in. Car is running well. The install was not as smooth as I planned. Has some issues with getting hoses reconnected, clearance in there is a little tight. Connecting the inlet pipe to the new turbo was a serious chore. Had to trim the TIP down quite a bit and the new turbo inlet has no lip on it to hold the hose. This became a headache for hours. Also managed to snap the retainer clip on the lower coolant sensor. Being held in with some copper wire at the moment. Have to pick up a new clip on monday.

Painted the valve cover while I was at it. and pulled out the boost reservoir. At the moment everything seems to be running great. I just have to deal with the smell of the freshly painted valve cover entering the cabin.

I'm really very satisfied with the current power level, dispite not having some key supporting mods in place. Pleanty of power when I want it, but I can keep the turbo under control. It's not constantly spooling up during regular driving. Loads of power at my fingertips if I choose to use it. And if not, it just waits in the background. Pretty awesome.

I'm pretty certain with the addition of intercooler, full exhaust and BT software (injectors) this will be more than enough power form my needs. And I can smell (literally) a clutch job coming in the future.

[turbo kraut]

i would stay as far away from boost until you get a tune and injectors..... i also have the uni file and have had a lean code/idle issue since day 1...... as soon as i can i'm going with a different tune

[ZimbutheMonkey]

Yeah, I said something about Eurodyne a while back but nooooobody listens to the crazy ol' Monkey

[IGottaP]

so its been some time how is it going? any new improvements any new problems etc etc?

[KFizz]

Yea sorry, been a while since I've updated. Mostly because not much has changed. Software and injectors have been purchased. I'm still waiting for the ECU to arive. I suspect that is when I'll get a good feel for what this turbo can do. For the time being though its performing well on the Stage 2 program. So all is well for the moment. Unexpectedly had to buy new wheels and tires recently. This set back the purchase of exhaust and intercooler a bit. I did however get a chance to install some 2.0 coilpacks and adapters and have been really impressed with the effect they've has on idle and general smoothness of the engine.

The only real complaint at the moment is my R1 diverter valve. I suspect it's leaking and I cant stand the sound it makes now. Sounds like a bird chirping or something, really fruity. My friends all get a good laugh from it.

So again, next step is getting the ECU installed (Revo). Then getting an exhaust, intercooler and TIP. I'll try to scoop these out of the classifieds as they become availiable. I'll try and do a better job of updating and taking proper pictures moving forward. I planned to photograph more of the turbo install, but it dragged on late into the night and i was becoming angry and was covered in oil and coolant. The camera took a back seat to getting the car back together.

Anyhow progress is being made, just slowly.

[KFizz]

How the hell do I get the damn connections off the fuel filter?!!*!

Sent from my HTC EVO, using Tapatalk

[Matt Devo]

How the hell do I get the damn connections off the fuel filter?!!*!

Sent from my HTC EVO, using Tapatalk

press in the tabs towards the body of the filter, then press the connector slightly up, then back off the nipple

[KFizz]

Update:

Recently I purchased some 2.0 FSI Coilpacks and IE spacers. Two weekends ago I got them installed along with the new winter wheels and tires. The winter tires have been helping out a bit. However our weather has been so favourable that I could easily have gotten away without them this year. Good to have regardless. At this same time I had my first run-in with the "widow maker". The jack fell over in the garage as I was switching wheels. Luckily the wheel was still on the car at the moment. Still managed to put a 3 inch gash in my side skirt though. I'd like to throw the thing in the garbage, but I think I'll keep it in the trunk for emergency situations. Never again for regular work on the car.

Coilpacks, as I've mentioned earlier, made a noticeable difference. I wouldn't say a power increase, but the engine feels much smoother. I'm quite happy with them. And I think they look nice in the engine bay.




This weekend I decided to take care of some mods of a more cosmetic nature. I had a carbon fiber replica Caractere roof spoiler lying around that I purchased a little while ago. Took a little heat gunning and some muscle to get it into the right shape. At the end of the day I think the fitment is pretty good.





Saturday I had the LED taillights tinted, something I've been wanting to do for a while and just never got around to. I didn't do these myself. I had them done professionally ended up being quite cheap in the end. $55.

Before


After


And then I tried to swap the fuel filter. And I say TRIED, because it didn't actually get done. This was extremely frustrating. I could not for the life of me get the rear lines off the filter. I read the DIYs, tried all kinds of stuff. By the end of it they never came off, all the tabs were broken, the connections are totally mutilated and one of the lines had a nice kink in it. Unbelievable. The 16 hour turbo swap was less frustrating than this. I don't get it, what the hell is the sense in having the rear connections different (more difficult) than the front ones. Anyhow, I'm upset about this one. Bested by a fuel filter. Not my proudest moment. I did manage to get the kink out of the one line. I'll have to replace the fuel lines running to the back of the filter eventually. Normally replacing them would be a priority, but quite honestly those f8%kin' things are not going to come off on their own, clips or no clips.

So basically this weekend was 2 steps forward, one step back.