Kesh's 77tsi Build Thread / Worklog

[Kesh]

Hey guys and girls.

I decided I'll try and keep a worklog of the things I do to the newest member of the family! The car is a 2010 77tsi Polo. This one just has the sports pack, and has done 120k.







The car is pretty much completely stock, the only modification being some carbon fibre look inserts on the rear vw badge. It looks pretty nice so I'll keep it for now!

[Kesh]

I've always been a bit of a car nut, and self taught myself CAD. I started a business last year called Atrax Engineering, just making car parts and stuff. I do hope to make a fair few parts for this car, a bit of a learning curve involved as this is my first euro!

First thing I've been designing is an oil filter adapter adapter. The main reason is I'd like to run an oil cooler, as well as a temperature and pressure gauge. There are plenty of sandwich plates around, but none of them are compatible with the 1.2tsi because our filters have a springed plastic piece on the bottom of the filter.

[OUR6R]

Interesting. Especially with VW and as a diesel mechanic myself I'd be checking the flow and pressure specs of the oil pump.

[Kesh]

It's something I considered. I abandoned that because the costs were just far too high. I will probably rely on water temps instead for the time being. For those interested, a much easier place to get oil pressure and temperature is the sender just on top of the cam cover. There are adapters made to tee off this sensor.

[amazeer]

Why? I've ran supersprints in mine and and never had a temperature issue.

[Kesh]

Peace of mind I suppose. My previous car had a head gasket issue and would constantly overheat, so it's just something that I want to know the state of when I feel necessary. I will probably stick to OBD2 at this stage as it seems to be working great.

It's also worth noting that the car will be tuned, and is very much a development platform, so any knowledge is power.

[Mountainman]

But can't you just read the oil temperature anytime on the multi-function display? Even under extreme driving conditions during this last summer in temperatures over 45C the oil temp maxed out at 104C which is well within a reasonable range. Average temperatures sees it sitting between 94 -100.

[Kesh]

Unfortunately, the 77tsi only has the basic MFD which means no Oil temps etc.. But I ran the car at the mountains a few nights ago and water temperature reached 99, but remained stable. Intake air temps are very high though. Venting the hood is my next little step.

[Kesh]

Also got a muffler delete and a conservative tune put on the car yesterday, has made a very sizeable difference to every day driving. 0-100 speeds were down from 11 seconds to 9.7 or so. Same conditions. Peak boost is 16psi, which will be brought up once I've had time to log everything and make sure the engine is happy.

As said before, intake air temps seem quite high, (53 degrees, 22 ambient), so I want to figure something out there as well.

[Lucas_R]

Kesh's 77tsi Build Thread / Worklog

Sounds like you want water injection which will have a huge effect on reducing intake temps. Are you sure the car is running 16PSI? Thats alot of boost for that tiny turbo, and no doubt contributing to your high inlet temps as these cars dont run a traditional intercooler. I thought they ran about 5-7 PSI stock.

Logged data for 77 TSI upgrade; local dyno runs will be performed in the near future.

[Kesh]

I have been looking into water/meth injection for sometime. Just trying to work out a more cost effective method at this stage. What puzzles me is that the intake temps are still quite high when cruising. One would think that the air flow through the heat exchanger will cool things down a bit.

I'm also unsure as to whether the iat is pre cooler or post cooler as there are two sensors. I believe it's pre cooler because the temps are quite high, but as said above, even at cruising when I'm on boost, it's at almost 50 degrees. Could be by design.

Regarding boost, I have seen that graph before and I've been puzzled myself. I'm using torque to log my boost pressures and I'm seeing 15.6psi peak at around 1900RPM. My tuner also ran some quick calculations based on the maps in the tune which produced numbers around 17psi.

Had a peek around forums as well and the general consensus is that these cars run just under 1bar of boost stock. So I'm actually not quite about what's going on with that graph, my peak boost is definitely before 2000 as well.

[Kesh]

double post

[Lucas_R]

I have been looking into water/meth injection for sometime. Just trying to work out a more cost effective method at this stage. What puzzles me is that the intake temps are still quite high when cruising. One would think that the air flow through the heat exchanger will cool things down a bit.

I'm also unsure as to whether the iat is pre cooler or post cooler as there are two sensors. I believe it's pre cooler because the temps are quite high, but as said above, even at cruising when I'm on boost, it's at almost 50 degrees. Could be by design.

Regarding boost, I have seen that graph before and I've been puzzled myself. I'm using torque to log my boost pressures and I'm seeing 15.6psi peak at around 1900RPM. My tuner also ran some quick calculations based on the maps in the tune which produced numbers around 17psi.

Had a peek around forums as well and the general consensus is that these cars run just under 1bar of boost stock. So I'm actually not quite about what's going on with that graph, my peak boost is definitely before 2000 as well.

The IAT on my Mk6 GTI (and my old Golf R) was on the inlet manifold just after the throttle body - therefore post intercooler. Not sure what the setup is on the 1.2T

Some discussion here about boost pressure. The Briskoda link seems to confirm your theory of 16PSI.

http://www.vwwatercooled.com/forums/f128/77tsi-turbo-63791.html

https://www.briskoda.net/forums/topic/184846-more-power-from-the-12tsi/

[Kesh]

The IAT on my Mk6 GTI (and my old Golf R) was on the inlet manifold just after the throttle body - therefore post intercooler. Not sure what the setup is on the 1.2T

Some discussion here about boost pressure. The Briskoda link seems to confirm your theory of 16PSI.

http://www.vwwatercooled.com/forums/f128/77tsi-turbo-63791.html

https://www.briskoda.net/forums/topi...rom-the-12tsi/

Yeah that's one of the threads I read as well. Might ask john what his graph is suggesting.

The IAT sensor is built into the map sensor on the 1.2 at least, and there's two of them, pre and post. I guess the definitive way to test is to unplug one of them.

[Kesh]

Quite the story to tell from tonight tuning session.

We upped the boost to try and achieve around 18psi, doing small incremental changes on each run. Each time, we drove carefully for a few minutes then did a pull on the freeway, so we can see where and when the boost is peaking. On the 3rd pull on the free way, the car hits peak boost of about 15.3 psi, and then it stutters bad, and the dashboard lights up like a Christmas tree.

We check the code on torque pro, and it's a cylinder 1 misfire. We limp it home, misfiring the whole way. We take the plugs out, praying to all the gods that the tip hasn't broken off, none of them were which was a massive relief. We did see some chipping or wear, but we weren't too concerned, so we swapped the plugs from a working cylinder, and cylinder 1 was still misfiring.. Uh oh...

What made me even more anxious is that the spark plugs were due in about 3000km.

Later on, I swapped the leads to 1 and 2 and the misfired moved to cyl 2, an absolutely huge relief. Having read up on it now, it's quite a common fault, but for it to happen mid pull at peak boost, was a gut wrenching moment.