Tiguan IS38 and Big turbo upgrades

[Melbourne_Tiggy]

Hi all,

Given the recent IS38 turbo upgrades by a number of the Tiguan mk2 community, I thought to start a thread sharing mods, experiences and issues relating to turbo upgrades. Australia is fast becoming the IS38 Tiguan country of choice.

Welcome!

Fast facts (as at 11/12/19)

5 x IS38 Tigs in VIC (2X APR, UGP 216 kw atw, Etuners 228 kw atw, INASANT Etuners 239kw atw)

1 x IS38 Tig in NSW (Tunehouse, 185kw atw)

2 x IS38 Tigs in QLD (Redline Tuning, APR)

1 x TTE475 Tig SA (E-Tuners Motorsport 240 kw atw mainline dyno)

1 x L450 Tig in QLD (Redline Tuning 255 kw atw)

1 x TTE475 Tig in NSW (E-Tuners 240 kw atw 1.7 bar)

1 x Snail 480 in VIC (E-Tuners Motorsport 265 kw atw - Tiguan all space)

Summary of OEM IHI IS38 model revisions (used on mk7-7.5 Golf R and S3) that are have been installed on Tiguans:

-06K 145 874 G
-06K 145 722 H
-06K 145 722 T
-06K 145 874 F
-06K 145 874 P (new mk7.5 turbo- Actuator similar to IS20)

With tuning, power of around 400 HP can be achieved.

OEM IS38 IHI Turbo Charger specifications:

-6/6 Blade Billet Compressor Wheel & 8 Blade Turbine Wheel
-45.2 mm Inducer / 58.0 mm Exducer - Compressor
-47.4 mm Exducer / 54.7 mm Inducer - Turbine

Summary of IS38 Hybrids that have installed on Tiguans:

-REVO IS38 ETR (500+ HP)
-The Turbo Engineers TTE475 (475 HP)
-Littco L450 (450 HP)
-Snail Turbo (480 HP)

List of known turbos that fit the EA888 GEN 3:

GTI turbo list

Includes price (usd), compressor/turbine, blade info.

Supporting parts:
- Tyres: Michelin Pilot Sport 4S

- Intake: APR, Racingline R600 w/ Turbo hose/elbow, BMC / k&n/ RAMAIR filter replacement/snow grate delete/intake modification

- Flow (APR, VWR, ECS tuning):Turbo inlet, Turbo muffler delete

- Cooling: Wagner Tiguan Intercooler, Forge and Lava turbo blankets, VWR oil cooler

- Ignition: RS3 Eldor Plugs, NGK 7437-9, Denso IKH24, OEM RS7

- Fueling: Autotech HPFP, VIS HPFP (Romania)

- Handling: Dogbone insert (VWR, APR, 034 motorsports, CTS), Pendulum Mount (APR, note make sure the mount is for a DQ500 MQB transmission).

- Lowering springs Eibach and H&R.

- Exhaust (APR,CTS, RD Technik): Downpipe & resonator delete, OEM golf R muffler (fits exhaust hangers, however needs some modification to fit re: remove fake exhausts, need to extend exhaust pipe and tips)

- Brakes (Alcon 6 piston and DBA T3 378mm discs). Check whether stock master brake cylinder is suitable or needs to be upgraded also.

[Melbourne_Tiggy]

The Tiguan started life as a 162 TSI Highline with R Line pack, tint, DAP and black metallic paint.

Note, those Suzuka 20” wheels with Pirelli Scorpion 255/40 R20 weigh 30kg each, some would argue significant weight to contend with. Anyway, to maintain the sleeper look, the stock wheels remain.

Mod journey:
Started the mod journey with an APR stage 1 ECU tune.......

Then progressed quite quickly to Stage 2.5 (some say stage 3). Current mods include:

-IHI IS38 turbo (revision H)
-APR IS38 v1.1 ECU tune w/ pops and bangs (original file)
-APR IS38 Beta v2 ECU 98 RON tune (updated file)
-TVS TCU DQ500 MQB Stage 2+ (Boost on LC enabled)
-Racingline turbo muffler delete
-Racingline DSG paddles (silver)
-APR turbo inlet (larger diameter inlet)
-APR AWD downpipe
-APR Dog Bone Mount Insert (Version 1)
-APR DQ500 Pendulum Mount
-NGK Racing 7437-9 spark plugs (gap 0.024”)
-APR Ignition Coils
-APR Carbon Fibre Open Intake
-RAMAIR intake hose/pipe
-Forge Diverter Valve
-DBA T3 rotors front and rear
-ATE ceramic brake pads front and rear

Other mods:
-DIY: Snow grate removal and air scoop modification to direct more air flow into the airbox like APR intake and R600 (gaffa taped rear left side of intake scoop and cut out the plastic directly infront of the airbox)
- OBDEleven: Changed digital dashboard to Golf R, removed legal warning on headunit startup, traffic sign assist, high beam assist, Scandinavian rear lights, reverse mirror dip.

Vbox Performance 0-100km/h
4.2 seconds (Pre TCU tune)
4.1 seconds (with TVS TCU tune)

Future mods
-APR, Leyo or Neuspeed boost pipes (charge and intake)
-Integrated Engineering, Wagner or APR intercooler
-Michelin Pilot Sport 4S tyres

Issues so far
-Metal rub sound on acceleration (resolved: tightened a loose exhaust clamp and used permatex exhaust and muffler sealant for the cat and midpipe joins)
-CEL P0137 Low voltage O2 sensor (resolved: installed a Vibrant J spacer and cleaned O2 sensor)
-CEL P2270 O2 running lean
(Installed IS38 APR v1.1 ecu tune without the pops and bangs, this did not fix the problem. I bit the bullet and changed to a new O2 sensor, so far so good)
-Fuel line rattle (fixed with foam around the fuel lines)

[TheTig]

DQ500 TCU tune is coming soon.

Interested to hear about this once you've got it done, who you getting it done through?

[Dose Pipe Sutututu]

pppplllllleeeeeaaassssseeeeeeeeeeeee upload logs

I love data!

RPM vs Load (MAP) vs Timing vs IAT (not AAT) vs AFR vs Injection DC vs Vehicle Speed

[Melbourne_Tiggy]

Interested to hear about this once you've got it done, who you getting it done through?

Hi TheTig, APR doesn’t currently offer a TCU tune, however I have been researching several European companies and contacting them for more info. I’ll keep everyone posted when I’ve made a decision.

[Melbourne_Tiggy]

pppplllllleeeeeaaassssseeeeeeeeeeeee upload logs

I love data!

RPM vs Load (MAP) vs Timing vs IAT (not AAT) vs AFR vs Injection DC vs Vehicle Speed

You are a data monster lol.

If I get a chance to do some logs I’ll post them for you.

[tigger73]

Hi TheTig, APR doesn’t currently offer a TCU tune, however I have researching several European companies and contacting them for more info. I’ll keep everyone posted when I’ve made a decision.

Suggest hitting up Simon at RD Technik as they are local and tune the DQ500.

They will custom tune shift points, increase shift speed, adjust torque limiters and can change launch rpm if you want. They are also the local Dodson Motorsport dealer (aftermarket DSG clutches) and have a Q5 as a daily so know this gearbox/limits better than most.

[Dose Pipe Sutututu]

You are a data monster lol.

If I get a chance to do some logs I’ll post them for you.

Can use VD to plot data

Oh yeah, log gear data too, so I know what ratio to use

[INASNT]

Purchased car, got bored with how quiet and non eventful it was after a few weeks...

Mod journey to date:
Stage 1
-Etuners Motorsport stage 1 ECU Tune including pops and crackles in sport mode (could not hear much with stock downpipe)
-Etuners Motorsport stage 1 DQ500 TCU Tune (4000rpm launch control setting, increased torque limits and shift speed)
-BMC panel filter
-Snow grate removed
-CTS turbo inlet
-Racingline intake hose/pipe
- GFB DV+ diverter valve
- Experimented with aftermarket rear muffler, put stock one back on after 2 days and was too loud and droned all through RPM range.

Stage 2
- CTS downpipe and mid pipe and 200 cel CAT
- 038 motorsport dog bone insert
- CTS 02 sensor spacer

Issues so far
- Downpipe hangers were too long and hitting subframe, trimmed a few mm from the ends.

- CEL P0420 Catalyst System Efficiency Below Threshold Bank 1. Without CTS 02 sensor spacer would come on after a few hours of driving, after spacer install came on 3-4 days after clearing. New file waiting to be uploaded once I get car back from panel beaters which will hopefully fix.

- Low throttle rattle at 1500rpm which sounds like turbo actuator arm rattle.

- High gear high throttle rattle from downpipe. Will be adding permatex exhaust sealer to all joins in dump pipe. Dump pipe should be made with flanges not clamps which would fix this problem.

Next Updrade
IS38 DBV2

[Melbourne_Tiggy]

Purchased car, got bored with how quiet and non eventful it was after a few weeks...

Mod journey to date:
Stage 1
-Etuners Motorsport stage 1 ECU Tune including pops and crackles in sport mode (could not hear much with stock downpipe)
-Etuners Motorsport stage 1 DQ500 TCU Tune (4000rpm launch control setting, increased torque limits and shift speed)
-BMC panel filter
-Snow grate removed
-CTS turbo inlet
-Racingline intake hose/pipe
- GFB DV+ diverter valve
- Experimented with aftermarket rear muffler, put stock one back on after 2 days and was too loud and droned all through RPM range.

Stage 2
- CTS downpipe and mid pipe and 200 cel CAT
- 038 motorsport dog bone insert
- CTS 02 sensor spacer

Issues so far
- Downpipe hangers were too long and hitting subframe, trimmed a few mm from the ends.

- CEL P0420 Catalyst System Efficiency Below Threshold Bank 1. Without CTS 02 sensor spacer would come on after a few hours of driving, after spacer install came on 3-4 days after clearing. New file waiting to be uploaded once I get car back from panel beaters which will hopefully fix.

- Low throttle rattle at 1500rpm which sounds like turbo actuator arm rattle.

- High gear high throttle rattle from downpipe. Will be adding permatex exhaust sealer to all joins in dump pipe. Dump pipe should be made with flanges not clamps which would fix this problem.

Next Updrade
IS38 DBV2

That is exciting mate, can’t wait for your DBV2 IS38 swap!!!!!!

We need someone to make a bolt on Tiguan muffler. I saw Remus one that was custom made for a Tiguan in Hong Kong, but this was not available in Australia. If anyone knows of an off the shelf muffler please chime in.

[TheTig]

Good idea for a thread!

Waited almost 12 months after purchase to put a bit of extra life into the car. Absolutely loving the power and exhaust note with all the work done!

1st Step

- Stage 1 APR tune
- BMC hi flow filter
- Snow grate removal

2nd Step
- APR Turbo inlet pipe
- ECS silicone turbo hose
- APR downpipe
- Stage 2 APR tune
- Airflow mod into airbox

3rd Step
- IS38 Turbo
- APR dogbone
- APR turbo muffler delete
- Stage 3 APR tune

Maintenance

Going to perform oil changes every 7,500Kms from now on, in-between 15,000km services

Issues

- Initially with the stage 2 mods had a metallic type rasp out of the exhaust starting at low revs and when accelerating, made the exhaust sound a bit tinny. Not happening now, put it down to new DP and also new rear muffler that was replaced due a rear end accident. Now the've both got a good layer of carbon the issue appears to have gone.

Next upgrade

- Pops and bangs tune, waiting on APR to release it for my car
- Maybe a TCU tune, will see what happens in this space first
- Lowering to improve the on-road stance has crossed my mind, but don't want to be scraping the front end on steep driveways

[Hole46]

How’s the fuel economy on these IS38 beasts?


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[INASNT]

That is exciting mate, can’t wait for your DBV2 IS38 swap!!!!!!

We need someone to make a bolt on Tiguan muffler. I saw Remus one that was custom made for a Tiguan in Hong Kong, but this was not available in Australia. If anyone knows of an off the shelf muffler please chime in.

I did look at dual magnaflow muffler's when playing with my rear muffler which was a recommendation from the exhaust shop.

[tigger73]

How’s the fuel economy on these IS38 beasts?


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It’ll be depending on the application of the right foot.


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[TheTig]

It’ll be depending on the application of the right foot.


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Ditto, just filled up the 1st tank after the IS38 install and Fuelly reported 10.7.

So if you've got a lead foot, it'll suck the go juice like nothing else, but it can still be quite good if you treat it nice