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Kesh's 77tsi Build Thread / Worklog

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  • #16
    Did some testing, my intake air temp readings I'm seeing are actually post cooler, so I'm not too happy with it, even if it is by design as the car is happy.

    I will be combating the issue in a few ways in the near future.

    1. I will be installing a new intake, this will likely make absolutely no difference to temperatures or performance, purely just for acoustics. It's a cheap universal one off ebay which I will modify for use on the polo.

    2. Venting the bonnet. I'll be installing a large vent around the middle to the front of the bonnet to promote hot air to escape from the under the bonnet. This will also reduce the pressure differential between the front and back of the radiator, which will mean a more effective radiator, and theoretically, also an improvement in aero.

    3. Meth/water is unlikely, will outline below as to why. I am looking more into a water spray for the heat exchanger. I have heard good things about the effectiveness of these sprayers. I have bought some misting nozzles and I'll couple that with a high pressure pump and see what the results are. I have no idea what to expect, but theory would suggest a reduction in iat.

    I've chosen against meth injection for a couple of reasons. Firstly, it is rather complicated, and whilst doable, there is a lot of wiring, tee-ing and sensors to plumb in. Secondly and probably the biggest factor, is the design of the intake system. The charge air pipe is a non standard piece of plastic with no real flat surface which really limits the chance of a nozzle having a good seal when installed.

    Pre turbo injection is quite a bit easier, however there's a lot of info to suggest that unless the mixture is properly atomised, there is a great chance that it can damage the blades of the compressor housing. Not worth the risk.

    The cool thing is that these modifications are quite inexpensive and will put less stress on the engine for a given target, not a lot to lose.

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    • #17
      Hoping my leads will come tomorrow sometime. Been almost a week since I've driven the car. Meanwhile, my ebay intake arrived, so I wasted no time doing a rough install.

      With the stock pipe coming from the cold side of the turbo, it is quite a tight fit, there's on flimsy bracket but I'll do for now.

      Will have installed pics when I get home

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      • #18

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        • #19
          Did some more tuning today. Very happy with the results, it seems to be a bit lean on the transition from off to on boost. But I've put this down to just requesting high engine loads at too low an RPM, but for logging sake I did it anyway. Never the less, the car was still happy, didn't pull any boost as you can see from the graph so I know that there's no detonation happening.

          Full boost is achieved at 2000RPM which I'm stoked about, but unfortunately, there seems to be a boost cap set at 1.1bar which is stopping me from getting 18psi like a lot of people have been getting.

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          3 very consistant runs, requested afr's match measured afr's well.

          Only hiccup was finding that the air filter had come off at some stage.. So I'll have to figure out a way to tighten it more securely.

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          • #20
            A very eventful night.

            After doing months of retunes, it feels like progress was being made, however there were some issues. The car was going into an enrichment mode where it was dumping fuel after 3000rpm for some reason. The car only managed a measly 55kw on the dyno. It's obvious that something had gone wrong at 3000RPM in the graph as it dips and refuses to climb.

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            • #21
              Tonight he made a break through, found out that the intake I put in has been the main source of all our issues. During the last flash, the computer had crashed, which was a heart stopping moment for both of us, but luckily the tool recovered itself properly and the flash continued after the computer was restarted. AFR and boost is absolutely spot on, 0-60mph is now at 8.7 with a passenger, a vast improvement from 11 seconds completely stock.
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