Hello!

To introduce myself and my car I figured Id make a project thread about it.

I bought the car a few months ago thinking it was almost all original.

I knew that there was a Milltek fitted.

Seller said catback.

After only 40km on the way home, EML litt up.

And from there it goes.

Private sale so no warranty.

Limp home mode was active.

Fault code about boost lower then expected.

Luckily i had brought my simple obd2 code reader/eraser.

Of with EML drove carefully the whole way home.

Excuse my language, Swedish native.

I had a look here on the forum and googled a bit.

Loads of black smoke, whistling and no boost was the most obvius symptoms.

Luckily it was only a boost hose!

Made a gipsyfix to be able to keep driving untill i had all parts.

Loctite glue and "silver" tape.

Sturdy fix, beeing this side of europe getting parts here was not cheap.

Ended up ordering turbo hose adapter from Darkside. Ordered for the egr to.

Edited 18 July, 20169 yr by tonysandberg

Fixed is fixed! Got many of us home has a roll of tape!

So i replaced the hose with 2.25 alu pipes.

Pipes and siliconehoses from do88.
Aba clamps from work.
Also bought some 4mm siliconhose for the vacuum equipment.


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Edited 19 July, 20169 yr by tonysandberg

The AC was not working, the forge intercooler had grinded a hole in the condenser and vise versa so I still have a small hole in the IC that I will solder later.
Replaced ,vacuum and refilled

 

 

Edited 19 July, 20169 yr by tonysandberg

During this time I started doing som research about the car.

I knew something was done to it.

First when checking the boost pipe on a lift I saw that it was not a cat-back exhaust but turbo-back with 200cell cat.

Thats not bad but it needs refitting due to having the leveling sensor for the xenons( wich are not on the car for some earlier MOT issues)

It makes allot of vibrations in the car but with some luck all I need is new hangers/rubbers, if I lift it just a few mm it gets clearance.

I had some info of a friend to previus owner that told me " it was built by Stertman Motorsport"

So i contacted them too see.

After a few calls fort and back about who was owner when they had it most got cleared up.

When they built it in 2012 they fitted

Bigger turbo(Said GT 1756 from beginning but unclear now)

Uprated clutch on org dualmass( hoping and guessing sachs SRE.

Some bhs intake system(open airfilter and a pipe to it.

Yellow konis

Hr springs

Adjustable Front strutbrace (unknown brand yet)

Turboback milltek with 200cell cat.

Giac custom tune.

Forge Fmic with pipes.

This was a bit of the books build so exact info is missing on the turbo that a dealer replaced in a warranty claim to the owner before me. Sadly enough with a reman Delphi hrx 325 that is a direct replace for the OE turbo.

And on the clutch, but both turbo and flywheel will be replaced.

started polishing a bit.

New cam, blacktops and bearings.

New injector seal kitx4

X-man turbo.

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Edited 19 July, 20169 yr by tonysandberg

Very nice parts!

Pretty much the jobs i've just finished on mine. What power are you hoping to get out of it?

Very nice parts!

Pretty much the jobs i've just finished on mine. What power are you hoping to get out of it?

 

Goal is 200bhp

Very nice parts!

Pretty much the jobs i've just finished on mine. What power are you hoping to get out of it?

How did you do with the rockers? reuse or exchange?

Very nice.

What Xman Turbo did you go for?

Very nice.

What Xman Turbo did you go for?

 I went with the 1752 hybrid...

Nice. I run the same Forge intercooler on mines and will be going for the same turbo and same power goal so will be interested to how you find it.

Nice. I run the same Forge intercooler on mines and will be going for the same turbo and same power goal so will be interested to how you find it.

Allright, to be honest when checking temps I was expecting better but it is very nice fit and oem look.

But mind the condenser behind.

Mine had rubbed so much that there was holes in both so had to replace the condenser and going to weld/solder the small hole in the intercooler.

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I found the same. Mines has a remap and unknown turbo on it just now and driving it hard it can hit 60oC on intake temps. What are you getting? I was tempted to go for a 1756 turbo but the 1752 seems better for daily driving and long term reliability.

I've had the 1752 for over 2 year now, still trouble free at around 220bhp, but think that was pushing it a little.

Starting to get shiny! Going to try som blackwax tomorrow!

Edited 25 July, 20169 yr by tonysandberg

Whats the verdict?

 

 

 

https://youtu.be/_98YrBR-bU4

 

EDIT: Tried to upload a video via mobilephone, did not work.

Edited 27 July, 20169 yr by tonysandberg

does anyone know the size of the coolant hoses going to the egr cooler?

Boom went the turbo!
second gear after a speedbump, not really much throttle like 30-40%

Was it smoking or making any weird noises before it went boom?

Was it smoking or making any weird noises before it went boom?

no real hints, little bit more whine but not much

So finally got the car to the garage last night, going to start the turbo replacement asap, plan is to start dismantling tonight but I only have 2h tonight.

I will be following  the instructions in http://www.briskoda.net/forums/topic/307517-guide-19-pd130-turbo-installremoval/  and real cred to the guy who made this.

So I got to the garage last night and got started, I was only planning on rising the car and maybe putting some oil on manifold bolts but I actually got further than planned.

 

 

 

 

 

 

 

So I got intake,egr,asv,the pipe to the turbo, airbox(to clean), some of the exhaustmanifold nuts off.
Tonight I will focus on getting the intercooler and piping off to start the cleaning in a bath of diesel.

 

 

Got this for the egr delete, for the blanking plate.

 

Doesn't seem right to put a soft gasket there, am I wrong?

 

Next up after turbo is this...

 

My new garageshirt...


 

 

 

got more done than expected today to....

Intercooler, piping and turbo out!

The gasket for my EGR delete was metal, the pipe further alone from the manifold is that type though.

good progress anyway

I was out last night to, I say nights because I work an 11h shift 100km from home so roughly 2-3 hours of commute by car everyday...

Clean out the intercooler pipes and hoses, put the manifold in a dieselbath although it wasn't so effective that I had hoped but I left it in there over this night and will bring some ovencleaner with me tonight incase the diesel didnt do the job.

regarding manifold,egr,asv Id say I was missing about 6mm in flow capacity...

I tried to clean the intercooler to but I suspect I need a doover for that one, expected some more debris from the impeller.
Found a lot of debris in the hoses and pipes, some of the hoses had pieces actually stuck in the like it cut in to the silicone.
The one directly by the turbo had taken a real beating inside.

 

 

 

The gasket for my EGR delete was metal, the pipe further alone from the manifold is that type though.

good progress anyway

alright, good cause I put the old metal gasket on there instead.