James GTI Ko4 2.0tfsi 401bhp - launch control?

[james]

I got the car around the 15/03/11 - Leather, 18" monza, winter pack and a few other bits.

Stage one remap with Angel Tuning


The plans where to do the following
Whiteline Anti lift Kit
S3 turbo kit
THS intercooler
Anti-roll bar kit
Highline computer
RCD510 DAB
BBS LM Alloys
LSD
Full Miltek system, with r32 arse

The mission was 340BHP

The car has been in the garage longer than i have owned it  

........................................................................................

The first thing i done was to install a genuine golf mk5 bra



Then install Evoms intake/ heat shield & Open air intakes



I must say i was very impressed with the sound and performance increase mid-range.!

Then installed my open air vents to help with heat soak




Then i went about spending 4hs of my life installing the IC

The day begun by me stripping a few bits off the car and also removing the bumper,


I then removed all the IC pipes and found myself a nice little boost leak, the stupid C clip had slipped off



Once all the pipes were removed, i had to remove the front panel!  This part was rather interesting. I had to balance all the rads with one hand while pulling away the front end!  Job done after a few magic tricks.
I supported the rads with some axel stands and went about removing the standard IC from the rad pack

new v old


Then i installed the new IC in place

Then put all the back together!!   Witch was the easy part

You really could tell the difference once you started to do lots of sprints... the recovery time was fantastic

On the same day i installed the Walk anti lift kit (very easy job)

[s3dubbin]

Is that an angle tuning map or angel tuning map? Liking the mods, cant wait to fit my THS cooler later this month. Cheers, Stevie. 

[james]

OK

The next thing i done was installed the K04, S3 injectors.


With

Neuspeed K04 discharge pipe

Neuspeed Hiflow IC pipe

Forge Throttle body hose

Forge coolant hoses

Forge DV hose

Full milltek system

Neuspeed front n back anti roll bars
APR HPFP
THS engine mounts


I cant find any pics of me installing them.... :(  think they are on another pc somewhere



I then installed the forge catch can, carbon filter covers







The car then went to AMD for a custom remap   and it went abit wrong

Here is the RR


The car had mega over boost and would limp all the time     I had so many problems it went back and forth for weeks.... I got a full refund and they left the map on the car  
that is the short story version.

I then dragged the car to nick at r-tech for a custom remap!



This was nicks information
.............

A bit of a task this Mk5 GTi with S3 turbo/injectors and HPFP.  
The hard part was getting the fuel constant via the air flow correct so the fuel trims are within reason,and the injectors not dumping fuel as the turbo is spooling.  Step1 re-scale injectors on a stock map and set the rail pressure maps to work with the HPFP, this took around days of trial and error testing and logging.  Next step was to tame the boost and make sure I had full control, the first thing I noticed with running the k04 on the k03 mapping was that under load at higher rpms the boost would creep off the scale, I would ask for around 2250mb, the ecu would ask for the correct load and boost but becuase of the k03 n75 mapping being on a lower scale the n75 realted maps would allow too much duty cycle.  So it was another 2 days getting the boost correct and with in maps sensor range and having the n75 act for the k04,  it got the the point that the actual boost was running 200mb below the requested line... at this point I had safe control so time to wind the n75 up in increments to give a little spool up over boost which just clipped the 2580mb map sensor and fall back to the requested boost 2400-2300mb. Next task was timing nice and easy to get a base point as the S3 timing maps and scales fitted in place nice..   now just a matter of keep adding the timing in until the ecu started to pull back on the correction of the car stopped making any more power.

I have really enjoyed doing this job as I was taking a lot on doing it, but knew with enough time I could get it bang on. I had no aim of chasing peak numbers, just a car that pulled and pulled like a bitach to the red line.

The final result was 335bhp 310lbft @270.25gs..... £80 woth of fuel used on the dyno and road.

................

I took the old girl to the track

[james]

I then installed the r32 Brake setup


I thought they where fantasic but needed somthing more as they would heat up to fast (track)


Installed Canbus update and rcd510 DAB  ( What an arse!)



Installing this was harder than fitting the turbo!! i smashed my head and hands up for this!

I did not have a DAB connection so used the FM worked fine.




Recoded with vagcom

I then installed installed Highline clocks and created a read me for everyone
How to, Midline to highline retrofit
http://www.mk5golfgti.co.uk/forum/index.php/topic,33055.0.html




add more in a sec

[james]

I had loads of problems burning plugs due to my remap so nick(r-tech) wanted the car back

I think he installed..
NGK Iridium X

That corrected the problem.

I then needed to upgrade my brakes again  

AP Formula Big Brake Kit

These brakes are fantastic!

I then wanted more power so the only way was!!



Picture of it installed.



I think nick said the car made 380BHP can’t remember the torque!

She was ready to be collect, then had an electric fault.  It has been at r-tech for 6 months.

It has had,
New, Throttle body, engine loom, sensors, Pedal,   and still goes into full limp mode at wot :(


I have a b16, LSD, Clutch, TT arms left to install.


Sorry about being picture heavy, is a years’ worth.

[Squeeguk]

Wow, that's a lot of work gone in there. Must have cost a small fortune. Hope you get it all sorted soon.

[mvb12]

where the hell do you get them bonnet bras from?

[N13SCB]

Great project 

[Top Cat]

Another mad modder.    great thread so far. 

[Andy]

wow excellent build thresd,sorry to hear its haveing problems think i would leave the water meth of the car

[james]

where the hell do you get them bonnet bras from?

i think it was top cats 

[james]

wow excellent build thresd,sorry to hear its haveing problems think i would leave the water meth of the car

no the water meth has to stay    i am just injecting water no meth so it is fine.

[Weston]

Saw this in the flesh today. Gonna be awesome once it's sorted 

[R-tech-Nick]

There will be an END!!!    I have had Rob cleaning all the earth straps today..... how many earth points does a mk5 bloody have..lol

374bhp 350lbft was best result with RS4 valve and 130bar of rail pressue on vpower.

The plugs used where Nology silver tip plugs gapped to 0.75 which cured the missfire issues straight way. I have used them on a few TFSI engines now which had been eating coil packs and eliminated the issues.   We had a Revo stage2+ BWA ko4 S3 injectors in yesterday on the dynodaze rolling road with exact same misre and eating coil packs, I sent him down the nology route.  He managed around 354bhp 378lbft.

Nick

[james]

got a call from nick!  he has fixxed my car!!

should be able to pick it up next mid week! woohooo