Anna's VW GLI DSG
 

Got this ride for Anna about a year ago, and it might have been this that spurred Kracka into ditching the torqueless S2k and move towards the dark side. At the time, I threatened him with the fact that my wife's car was going to be as fast as his. :D

Well, as life goes, a year has gone by and no mods to it yet, so it is high time to get some stuff done! For those that don't know, this is a direct injection 2.0 liter with a K03 'sport' turbo, and VW's dual-clutch DSG tranny (can't shift faster than this thing!). Just FWD, but it works. Stock is 200hp/209tq

Here's the plan for now:
-Neuspeed intake
-Kracka Vents (leaky PCV's are horriffic on these 2.0t motors for some reason!?!)
-EPL Stage 1 chip (raise boost to ~18psi, tune AFR and timing to some nice base levels, and improved fuel economy (over the 32-34mpg highway it already gets :) ) Similar chips advertise +50hp and +100tq (crank)

Later:
-forge DV (aka bov) unless something similar catches my eye
-ebay downpipe w/ cat delete

Goal: 200whp/240wtq on DB's dyno. Simple enough?

We started today with the neuspeed intake.

http://www.scheides.com/albums/gli/IMG_6865.sized.jpg

http://www.scheides.com/albums/gli/IMG_6866.sized.jpg

http://www.scheides.com/albums/gli/IMG_6867.sized.jpg

http://www.scheides.com/albums/gli/IMG_6868.sized.jpg

http://www.scheides.com/albums/gli/IMG_6870.sized.jpg

http://www.scheides.com/albums/gli/IMG_6871.sized.jpg

The stupid engine cover that comes on these cars stock is just dumb. We broke it getting it off, just a dumb design, as you have to just yank the crap out of it to get it off the rubber nubby things underneath it.


http://www.scheides.com/albums/gli/IMG_6872.sized.jpg

Of course, it cracked, and this engine cover is also the stock air box...no turning back now!

http://www.scheides.com/albums/gli/IMG_6873.sized.jpg

Yanking off the stock tube going from air box & maf to turbo:
http://www.scheides.com/albums/gli/IMG_6874.sized.jpg

Installing maf and intake pipe (note the sweet heat shield under it, she put that on too!):
http://www.scheides.com/albums/gli/IMG_6877.sized.jpg

All done!
http://www.scheides.com/albums/gli/IMG_6878.sized.jpg

Yes, I did help, but Anna did most of the work. If you have a 2.0t, I highly recommend this intake, great bang for the buck. Got it from Deviant Speed. Anna likes the new turbo sounds her car makes, you can *really* hear the turbo and DV now!

Kraka vents on sunday and then EPL chip goes on June 14 or 15th, should have some dyno numbers then :D

Re: Anna's VW GLI DSG
 

Making moves!

Re: Anna's VW GLI DSG
 

looking good! so one thing I want to do to my tdi is some aluminum i/c piping... you should look into that and that "spare" fmic that is chilling on your wall about the toolchest!!

Re: Anna's VW GLI DSG
 

looking good. good thing you did not do all the work you would have broke it worse

Re: Anna's VW GLI DSG
 

I love the way the new VW's look.


Looks great! Can you feel a difference in the seat of your pants with that intake?

Re: Anna's VW GLI DSG
 

ahh the good ol K03 "sport", just a little guy lol! but they make some good power

Re: Anna's VW GLI DSG
 

I guess there's no performance advantage on this particular car to switching out the piping, so I'm not in a big hurry to do it :D

No shit! There's a nice aftermarket cover that replaces the stock one that we'll be getting for it. This one is metal though, so less chance of breakage:
http://i53.photobucket.com/albums/g5...3/DSC00302.jpg
(note the shortened end of the intake pipe and also the alky kit on this car, woot!)

I haven't even driven it yet, just Anna. You can *clearly* hear the turbo when doing part throttle stuff though, I seriously have looked over my shoulder several times wondering if there was a semi next to us or something :D

I think that's what it is anyways, these cars come with a 'turbofold' like the srt-4. There is a K04 upgrade out there (wank wank) but the gains are marginal.

They do make bolt-on GT28rs/2871 kits though, I guess upgrading the FSI fuel pump on top of the motor is more than enough fuel for a setup like that....hrm....

Re: Anna's VW GLI DSG
 

Mine came with the k03 sport turbo also. They say that the k04 is a big upgrade for these cars? Not sure how much bigger the turbo is though. My NeuSpeed intake made the turbo and "diverter valve" really loud also. Sounds like a semi!

Re: Anna's VW GLI DSG
 

The Ko4 turbo is an upgrade but it isn't that much bigger... The Ko4 is the same turbo that is in the audi TT which has more power...

Jetta 1.8T 160hp
Jetta 1.8T GLI 180hp
Audi 1.8T TT 225hp

Just thought I'd share the info...

Re: Anna's VW GLI DSG
 

their are two jetta 1.8t older models had standard ko3, what you stated as the 160 hp. 2001 and older. 2002 and newer that the ko3 sport which came with 180hp stock. The FWD audi TT came with the ko3 sport, 180hp. I believe they put the ko4 in the audi twin turbo motors and the awd TT came with the k04

Just fixing your numbers :)

Re: Anna's VW GLI DSG
 

Looks good! But, sorry to say, I think the GLI would need a lot more work than intake, exhaust, and chip to be able to run with my ex-S2000! I'm excited to get some KV's on that thing and get a test-ride in it :)

Re: Anna's VW GLI DSG
 

Looking good!

Re: Anna's VW GLI DSG
 

AwdGsx13 I think you are correct in your turbo-per-model-and-year specs, except the 2.7t (twinturbo v6) audi motor came with only K03's. K04's are the 'big' upgrade for them as well as the old 1.8 cars, and honestly, it is a big waste of money. Kinda like upgrading from a 14b to a small16g, except a K04 is *smaller* than a 14b even. :P

Took the car for a spin a while ago, and in addition to the new fun noises it makes, the car feels stronger through out the power band. Most people report 5-9whp gains, and it feels about like that.

Re: Anna's VW GLI DSG
 

lol, i have to work on these cars all day and now come on here and read about it!

I hope everything goes well. If you need some discount VW parts i can get them 10% over cost for you ;)

Re: Anna's VW GLI DSG
 

ahh your right, I wouldn't waste the money. Back when i had mine they told me to upgrade to this turbo? Didn't see the point in wasting the money lol!

Re: Anna's VW GLI DSG
 

nice

Re: Anna's VW GLI DSG
 

Looks good!

Re: Anna's VW GLI DSG
 

Played a little hide-and-go-seek today with a kracka vent:

http://www.scheides.com/albums/gli/IMG_6920.sized.jpg

http://www.scheides.com/albums/gli/IMG_6921.sized.jpg

The factory PCV system SUCKS on these cars, there are SIX revisions to the stock system because they factory valves keep leaking, even at stock boost levels. Each new valve is about $100 from VW. So, one KV in the front, maybe another one in the back. Problem solved!

Re: Anna's VW GLI DSG
 

Situation solved :)

Re: Anna's VW GLI DSG
 

We were supposed to chip the car this weekend, but there was a mistake with shipping Tony (from EPL)'s equipment here for the flash. Stay tuned, maybe we'll get a downpipe in the meantime ;)

Re: Anna's VW GLI DSG
 

thats a pretty nice car. i like that she did most the work.

Re: Anna's VW GLI DSG
 

Update! EPL stage 1 chip, DSM Recirc'd DV, and Prosport boost gauge installed!

A few weeks back I went to vegas, and while I as out of town I let Tony @ EPL (European Performance Labs) throw their stage 1 flash on the car. I did before/after logs with Jordan at CPS here in MN and we saw boost rise from ~13 up to 18 peak, clean up the AFR, and timing looking strong. I was impressed, but something was not quite right.

I decided to ditch the stock DV, as everything I see about it makes me want to cry. I took the car apart and removed the noise box from under the dash and used the main portion of the hose to plumb in a BOV from a 1997 Mitsubishi Eclipse GSX. I had originally planned on using one out of my evo, but this one held 20psi just fine, so it will stay for now.

http://www.scheides.com/albums/gli/IMG_7993.sized.jpg

http://www.scheides.com/albums/gli/IMG_7994.sized.jpg

http://www.scheides.com/albums/gli/IMG_7997.sized.jpg

Next, block off OEM DV with ATP's plug:
http://www.scheides.com/albums/gli/IMG_7974.sized.jpg

http://www.scheides.com/albums/gli/IMG_7975.sized.jpg

(this same 'kit' is available with a Forge valve for $300!!! YEOW!)

Prosport Boost Gauge w/ NewSouth Performance gaugepod:
http://www.scheides.com/albums/gli/IMG_8000.sized.jpg
I read the how-to on this, and yes you gotta remove the battery, but NO, you do NOT have to remove all of the crap from under the steering column. Just extend the wheel all the way out and down, pop off the one little cover, cut a small hole in the leather, and from there you can easily run power, ground, and the tube up to the top of the steering column.

Plumbing is nice and clean thanks to the factory wiring tunnel thingy:
http://www.scheides.com/albums/gli/IMG_7988.sized.jpg

$10 in parts to get manifold pressure to the BOV/DV and boost gauge:
http://www.scheides.com/albums/gli/IMG_7990.sized.jpg

The car feels like it actually has some power now :D We logged again and N75 Duty cycle is much lower, meaning the turbo is working less to provide boost, leading to cooler intake temps (not much though due to the stupid factory intercooler setup :( ). Boost is also higher, peaking around 19. This says a lot, the skirt on the stock DV was in good shape, but it was obviously leaking while under power somehow.

Up next, ebay catless downpipe!

Here's the link to the DIY I wrote on doing this BOV setup:
http://www.golfmkv.com/forums/showthread.php?t=60503

Hrm, could this be the car for name dat powa?

Re: Anna's VW GLI DSG
 

Neuspeed. AKA poo-speed, lol.

Just don't spend too much money on vw parts, if you can make your own (like I/C pipes and new fmic) please do that instead of buying an overpriced kit. For some reason, german parts, aftermarket or otherwise, are really really expensive for what you get.

Re: Anna's VW GLI DSG
 

Haha nice mods! Everything looks good, but I dont like that guage location, just looks odd. Do they make a vent pod at all? I know they do for the auuudiis.

Re: Anna's VW GLI DSG
 

It definitely is faster than it used to be!

Re: Anna's VW GLI DSG
 

Nice, looks like this thing is really coming together :)

Re: Anna's VW GLI DSG
 

Looking good, be fun to see howthe DSG does now with some more power!

Re: Anna's VW GLI DSG
 

Lets see a pull vid!

Re: Anna's VW GLI DSG
 

looks good all back in there

Re: Anna's VW GLI DSG
 

I think we require some pulls

Re: Anna's VW GLI DSG
 

Craig, it's a plan. The DSG seems to handle the power just fine, not like it's making 400wtq or anything, it's only a teensy K03. The turbine housing is about the size of my fist....

Re: Anna's VW GLI DSG
 

Name Dat Powah!

Re: Anna's VW GLI DSG
 

I then require a race

Re: Anna's VW GLI DSG
 

No racing, just FWD vs FWD, testing & comparing. When is your car getting tuned?

Re: Anna's VW GLI DSG
 

well it has all the base maps loaded I am trying to get them to email me the program because it wont load off the disk for some reason

Re: Anna's VW GLI DSG
 

$187 shipped for ebay downpipe :D :D :D

Stay tuned....

Re: Anna's VW GLI DSG
 

The TT came in the 180hp and 225hp variants. The 225hp is really peaky and pretty much sucks to drive because the turbo spools too quickly. Hopefully the Dub doesn't come out this way.

Re: Anna's VW GLI DSG
 

any guess on whp when everything is said and done?

Re: Anna's VW GLI DSG
 

The goal for this car has always been simple: 200whp on DB's dyno. It *should* make more than that with the downpipe, but I'm not counting on any of the other BS dyno sheets I've seen online. VW'ers have a knack of being particularly inaccurate in how they post numbers, use correction factors, crank numbers (LOL), etc. BEST guess is 225whp on Dyno Dynamics, and torque should be above that, maybe 235-240wtq. On MAP's dynojet all bets are off, no idea how that thing reads.

Steve, this car is the 2.0t, not the 1.8t. I know what you mean about the peakyness on the 225hp TT. It had the K04, this car has a K03, like the 180hp version, but spun up a bit more :) It is for sure an insta-spool turbo but with the chip power is smooth and linear, making power all the way up to about 6k, then falling off (6500 redline). EPL has done an awesome job of tuning this thing, it really is fun to drive, even just with FWD.

Re: Anna's VW GLI DSG
 

sounds good my car should be about at that aswell