How To: Custom FMIC (Welly) Install

[Bowders1]

Hi Folks not posted for a while but have been asked to do this guide and have folks complimenting me on various stuff which is really appreciated so here goes another guide.

Part 1 - Gathering the Parts and Prepping for Fitment

A custom FMIC install needs thinking about before you go head into it.

example of the welly cooler and typical dimensions.

http://www.toyosports.co.uk/3-universal-intercooler-type-b-600x300x76mm-piping-kit-1248-p.asp

You need to decide what route / options and parts you are going to need before you start to ensure less time car off the road.
If you don't you could end up with parts not around or available to fit.

Although this guide is for the welly cooler you could use this to basically fit any custom FMIC.


Options to consider:

- use existing car inlet manifold set up and custom route a charge pipe to Turbo using selection of hoses and alloy pipes.
- replace std Inlet Manifold with a BAM inlet from a Audi TT/S3 or Seat LCR with throttle on right hand side

This allow shorter pipework , better routing to FMIC .

This will increase cost , and messing around time. But for me was the only option as i wanted near OEM look and install.

Also to further add to this I used the BAM charge pipe which requires a custom hose from charge pipe to Turbo flange. The BAM 90' hose to turbo will not fit on our smaller turbo's the K04 has a 54mm flange(no silencer on turbo) The K03s has a 45mm flange as it has a silencer.

So i had a custom hose made up. will provide size to charge pipe later.

Parts needed

- Welly FMIC
- set of various hoses (will give size and length later)
- Bam Inlet Manifold
- Bam Fuel rail (if using BAM charge pipe)
- BAM Map sensor and pipe (if using BAM inlet) or a custom map sensor pipe
- Charge pipe to turbo 90' hose
- Bam Brake servo hose (only if fitting BAM inlet)
- brackets to hold FMIC to crash bar or slam panel depending on your fitting

Bam map sensor pipe (need to cut off the bottom flat bracket attachment)



Bam Map sensor / pipe ( with my installed VRS MAP sensor)



Map sensor difference if needing one



- Larger one is the VRS one (18mm)
- smaller one is the BAM one (12mm)


Part numbers for reference (these are BAM,) I used BAM as VRS went faulty in the end there is no difference other than size)




Bam Brake Servo hose is the smaller one in pic.




Injector rail difference (BAM is on the left) only difference is the shorter hose connections that do not hit the BAM charge pipe)



Hose's and pipework for the install



Bam manifold first prep work to clean and polish



and inside



Then manifold painted with black heat proof and polished again lol:)




Brackets for mounting cooler to Crash bar



This makes fitting look better than rubbish meccano.

Bam charge pipe has baffle silencer pulled out, as the K03s has silencer already. Did not want 2 as would reduce turbo sound



And of course the Welly cooler (mine was second hand and of course polished again:))



Crash bar painted



BAM Inlet manifold N112/N249 and cover bracket painted



BAM inlet bracket cover purchased second hand and cleaned up



Job ready to start



Bye Bye Forge.......



Please read my guide on how to remove front bumper if needed:

here: http://www.briskoda.net/forums/topic/284280-how-to-remove-front-bumper/?hl=%2Bremove+%2Bfront+%2Bbumper#entry4136181

Remove original inlet hoses and charge pipework





remove fuel lne's and plug and remove fuel rail (only if fitting BAM charge pipe)





remove brake servo hose



Old FMIC and bumper and Forge modded crash bar removed



Part 2 to follow soon........

[Bowders1]

Part 2 - Stripping down Engine Parts and Fitting cooler

 

Fitting Welly cooler to new Crash bar

 

Note it is very important to test fit welly to crash bar and to car to ensure cooler clears the radiator air con rad and all plastic cowlings.It is a tight fit. 

 

 

bolted to car 

 

 

 

close up of brackets

 

 

 

 

 

This activity below is only for BAM inlet being fitted

 

Fuel pipes undone and plugged

 

 

injector plugs removed

 

 

throttle sensor unplugged

 

 

All hoses removed from Inlet manifold and underneath bracket to block bolt removed then off with Inlet (scary)

 

 

Wiring loom needs to be stripped from insulation to feed original Map sensor to right side of car from left side. Plus throttle sensor wire needs extending, rest of sensors and loom are ok.  The trick is to carefully route left to right with all sensors apart from fuel injector ones.

 

 

 

Phenolic inlet spacer and new gaskets (x2) to fit back on

 

 

Gaskets on and wiring all cleaned up and insulated

 

 

Bam inlet fitted (new Bam inlet to block bracket bolted on to) not really needed but ocd steeping in again.

 

 

new injector seals fitted(apart from right hand side as snapped the dam thing fitting it in)

 

 

Bam fuel rail fitted and injector re plugged  

 

 

Bam charge pipe holder fitted

 

 

VRS throttle cleaned and ready to refit

 

 

Inlet manifold temp sensor cleaned ready for fitment

 

 

throttle back on  

 

 

hoses connected back in Inlet

 

 

[Bowders1]

Part 3 - Plumbing up cooler

 

VRS charge pipe and pancake pipe removed and new BAM charge pipe painted ready to go on

 

 

Bam brake servo line fitted 

 

 

std VRS charge pipe to turbo flange  90' hose (black) verses the BAM charge pipe to turbo flange

 

 

 

temporary new hose made up to fit charge pipe to turbo (before i got a company to make one)

 

 

 

 

Intercooler pipework to bam charge pipe fitted

 

 

Temporary hose fitted to Turbo

 

 

and then fitted to charge pipe

 

 

New custom made 90' charge to turbo pipe fitted

 

 

Charge pipe connected up and brake servo pipe with silicon join connected to inlet Manifold

 

 

Battery  tray removed and Fan power cables get plastic plug removed to allow BAM map sensor pipe to fit down there. Space is tight

 

 

no longer needed

 

 

Battery tray left hand corner cut back a little to allow for BAM map pipe

 

 

plastic conduit added to fan cabling

 

 

 

Map Pipe connected up from intercooler to throttle hose

 

#

 

View from front 

 

 

 

View from on top of tray, can see pipe is tight in there

 

 

Inlet bracket fitted

 

 

replaced std TT throttle pipe with a forge silicon pipe

 

 

DV and N75 hoses connected to charge pipe

 

 

Top almost complete

 

 

 

Plastic engine inlet cover added

 

 

Front shot with Intercooler pipework complete

 

[Bowders1]

Part 4 - Final clean up

 

Test fit of bumper, showed lots of cutting needed

 

 

Bumper work needed to fit up to FMIC hoses lot of plastic removed. need to do this to both sides.

 

 

 

 

Bumper fitted and looking almost complete

 

 

Bumper grills readded

 

 

[Adz_VRS]

Awesome Wright up Bowders!!! Any chance you can list the parts used and diameter sizes etc? I know this is very lazy but knowing things like the BAM charge pipe to turbo silicone hose diameter sizes (I know it was custom bit if give us others the chance to order one up too) will give us noobs a Head start and hopefully gather all parts for a one day fit.

But mate, wow! You go to some extent for us other guys and I for one appreciate Your efforts along with many other Briskis no doubt!!!! Well done

[Bowders1]

Awesome Wright up Bowders!!! Any chance you can list the parts used and diameter sizes etc? I know this is very lazy but knowing things like the BAM charge pipe to turbo silicone hose diameter sizes (I know it was custom bit if give us others the chance to order one up too) will give us noobs a Head start and hopefully gather all parts for a one day fit.

But mate, wow! You go to some extent for us other guys and I for one appreciate Your efforts along with many other Briskis no doubt!!!! Well done

Yep will do all that laters dude as took me 3 hours yesterday getting good pics and post together lol...

Sent from my iPhone using Tapatalk

[e30kev]

Top work Mark, really good write up mate, thanks again for taking the time to share your knowledge :clap: 

Now I just need to track down all these parts.

[kentphil1]

And the Bowders1 write up bar is raised yet again for us mere mortals , top work, really good write up.

[Bowders1]

You guys are too much...[emoji2] I'm overwhelmed.....

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[spudboy6]

Hello ,

I'm looking to do this conversion on my car , I have sourced90% of parts but have a couple of questions for you ,

 

I have got the brackets that clamp to the charge pipe , but what do I need to secure the clamp brackets to the engine ? , from what I can work out the front charge pipe clamp must bolt to a bracket near the AUX belt tensioner , can you tell me how you secured your charge pipe clamps to the engine please or did you leave it loose ,

also is there a company out there yet supplying silicone hose for K04 charge pipe to K03S turbo yet ?

 

other than that it all looks great ,

thanks scott

Edited 26 September, 2015 by spudboy6

[Bowders1]

Hi Scott think you are talking on Facebook . So can answer you there too. On the BAM engine there are 2 charge pipe clamps. One at the back of engine and one at the front left side . I only used the front bracket which is this one. http://www.ebay.co.uk/ulk/itm/262034105388 . It connects to the tensioner and then you need the semi circular clamps to fit on that bracket.

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[retroboost83]

great write up mate, did you ever get chance to list down all the required hoses etc

[Bowders1]

Hi Andy

 

In response to your question 

 

Those items you quoted seem to be for 3" or 76mm intercooler connections. You will have problems with that width routing and getting behind bumper, and i am sure that is not correct as that means all the pipes are same size as the welly cooler inlet and outlets.  

 

You can see my reducers have pipes thinner routing to it which are 63mm or 2.5"

 

 

This is what i used .

 

2 x 90 degree 63mm hard pipes with beaded ends
2 x 90 degree 63mm silicone elbows 
2 x 76 - 63mm straight (approx 100mm long) reducing silicone hoses(join from welly to 63mm metal straight pipe) 
2 x 63mm alloy beaded joiners. (approx 100mm)
2 x 45 degree 63mm silicone elbows (to connect 100mm metal joiners).

1 x silicon hose(63mm) to charge pipe(can use std TT/S3/LCR ones)

1 x silicon hose(63mm) to join map pipe to Throttle body on BAM inlet) Can use std TT/S3/LCR one

Std BAM Map pipe (S3/TT/LCR) to join to throttle body hose. (can get custom metal MAP pipe from Forge(but dearer)

14 x 50 -70mm jubilee clips (for all the 63mm joins) maybe able to reuse some of your jubilee clips from throttle and charge pipes) 
2 x 70 - 90mm jubilee clips. (for welly cooler silicon reducers)

 

Example of these hose below:

 

1 x silicon hose(63mm) to charge pipe(can use std TT/S3/LCR ones)

1 x silicon hose(63mm) to join map pipe to Throttle body on BAM inlet) Can use std TT/S3/LCR one (the S shape one)

 

 

hope it helps

 

Mark

[retroboost83]

thanks so much for this matey i shall get onto collecting the required bits

[JesseH]

Hi!

I've been looking from ebay samekind of FMIC with hoses and pipes and everything. This one on ebay is a little bit smaller than your's that you put in your car, but could this fit into my 2003 1.8t vrs octavia:

https://www.ebay.ie/itm/DIRENZA-SKODA-OCTAVIA-RS-1-8T-99-05-ALUMINIUM-TURBO-FRONT-MOUNT-INTERCOOLER-KIT/151188362967?hash=item23338756d7:g:~10AAOSwU9xUSj6W

 

 

//Jesse from Finland