Audi TT by _Dejan_ (Stage 3 = 340 HP)

[_Dejan_]

Sorry mate, I meant how do they perform?

I didn't want buy OEM anymore because they have been noisy(high whine) when I slowly brake at low speeds and OEM has also produce a lot of brake dust. After change noise has gone and I have a lot of less brake dust. But they are not for track days because after few(10-20) hard "stopping"(From 130-180km/h to 50km/h) I can fell losing brake power... but for same price as OEM ones they are better...

[_Dejan_]

It's time to show some progress :)

Collecting parts in my working room:


Brushes for intake valve cleaning:


Injector tools:


It's time for bigger intercooler :)








And hoses shipped together with intercooler:




Hose to connect DV Intermediate Flange:


Im buy from HG-Motorsport PCV Fix valve:




Original PCV:


Removed original PCV:


Installed PCV Fix:




Im also get HG-Motorsport K04 Turbo Outlet:




This is original one:




S3 Pressure Pipe:


S3 Air Pipe:


This is all for now. I still waiting some items which I will receive in week or two :)

[_Dejan_]

Because Stage 2+ is not enough Im make on my car Stage 3 :)

First Im find garage and park car :)


Then Im change intercooler and silicone hoses:




Im also buy Forge Motorsport Throttle Body Hose:




And buy "new" Throttle Body Motor(done 2500km) because old has sometime generate error:


Then Im take down intake manifold and clean intake valves...

Before:


After:


Before:


After:


Then Im protect holes, rebuild S3 injectors(change seals) and install them:




This time Im also install RS4 PRV:


Im put all together and start changing turbo...
Turbo prepared to install:


And installed:


Im make DV relocation harness to extend original cable:


Cam follower after 30k km on Stage 2+ last time to replace them:


Car already run, Im flash ECU with S3 injectors file but on tuesday I will visit company to make dyno tests and real remap...

[rdfcpete]

I see that I didn't show my summer alloys which I have on car few months :)

These are Fantastic Dejan  A great, simple but classy design.

Do you know what they are called or do you have a link at all please? I quite fancy a set for my A3 Black Edition 

Other mods are looking really good, stage 3 will be fun 

[_Dejan_]

I see that I didn't show my summer alloys which I have on car few months :)

These are Fantastic Dejan  A great, simple but classy design.

Do you know what they are called or do you have a link at all please? I quite fancy a set for my A3 Black Edition 

Other mods are looking really good, stage 3 will be fun 

you can find them by part number 8J0601025BH ;)

[rdfcpete]

Thanks Dejan, I think I've found a set on ebay.co.uk.

Are they 18x9J?

 

[_Dejan_]

Thanks Dejan, I think I've found a set on ebay.co.uk.

Are they 18x9J?

 

Yes they are 9JX18H2 ET52 :)

[rdfcpete]

Thanks Dejan, I think I've found a set on ebay.co.uk.

Are they 18x9J?

 

Yes they are 9JX18H2 ET52 :)

Cool!

What tyre do you run, 235 or could you run a 225 40 18?

[_Dejan_]

Cool!

What tyre do you run, 235 or could you run a 225 40 18?

I have standard 245/40/18 :)

[_Dejan_]

I have been on dyno(We make 53 runs) to get best remap and most HP from car. We have stuck at 340HP and nothing doesn't help increase it. We are limit torque so this is not max what turbo can do because I don't want broke DSG...
This is what we get(red curves are Stage 3, blue are Stage 2+):

[edd30]

Dejan,
great build thread, you've been making very good progress.

Did you remove the inlet manifold and other bits and cleaned the inlet valves ? What happens to the carbon ? It'll hit the turbo blades ? Then block the cat ?

Did the IC fit on ok with no modifications ? Is it like this one ?
http://www.ebay.co.uk/itm/UK-VW-GOLF-GTI-06-10-2-0T-TURBO-MK5-FMIC-INTERCOOLER-KIT-VERSION-2-/331368888539


Core length: 24"
Core height: 16"
Core thickness" 2.25"
Inlet / outlet : 2.75"
End to end length: 28-36"

[_Dejan_]

Dejan,
great build thread, you've been making very good progress.

Did you remove the inlet manifold and other bits and cleaned the inlet valves ? What happens to the carbon ? It'll hit the turbo blades ? Then block the cat ?

Did the IC fit on ok with no modifications ? Is it like this one ?
http://www.ebay.co.uk/itm/UK-VW-GOLF-GTI-06-10-2-0T-TURBO-MK5-FMIC-INTERCOOLER-KIT-VERSION-2-/331368888539


Core length: 24"
Core height: 16"
Core thickness" 2.25"
Inlet / outlet : 2.75"
End to end length: 28-36"

hi,
Yes Im remove intake manifold, because Im instal S3 injectors... In same time Im make valve cleaning... When you cleaning valves your piston MUST be in TOP position!!! Before you go to next cilinder valves you MUST vacum all carbon so you can't have any carbon part in your combustion chamber because it will make damage to your engine!!! When you finish cleaning first cilinder you must by hand turn your engine "belt" and top next piston...

IC fit without modifications. Only part which missing are BOLT's and you can't use original ones... It looks same but I can't confirm if is real same :) My cost me 220GPB with shipping but now has seller increase price and cost 560GPB with shipping to me...

[edd30]

Ok -
remove intake manifold
turn the engine with the spark plugs removed so it is TDC (inlet valves closed)
then you use those brushes with an electric drill, then use a vacuum cleaner to suck out the carbon ?
Sounds risky to me, I don't have the courage to do it! So this is the negatives for TFSI ... dirty inlet valves.

[_Dejan_]

Ok -
remove intake manifold
turn the engine with the spark plugs removed so it is TDC (inlet valves closed)
then you use those brushes with an electric drill, then use a vacuum cleaner to suck out the carbon ?
Sounds risky to me, I don't have the courage to do it! So this is the negatives for TFSI ... dirty inlet valves.

Im make mistake. Valves must be closed and not piston in top position... Im not mechanic so not shure if valves are close when piston is in top position but if I remember it is. So important thing is that valves are close, that carbon parts don't fall into combustion chamber...
Im using brushes without eletric drill and Im do cleaning by hand brushes (better feeling to not damage anything) ... Im using brushes from THIS link... Im use vacum cleaner to suck out carbon and also air compressor but protect outside engine because you will have carbon everywhere :) Also use protection glasses!!! First cilinder Im do by wet process with using Liqui Molly Valve Cleaner, leave valves wet and after few minutes start cleaning them. Im find that dry process is easier and easier to suck carbon out... So all other three cilinder valves i do without liquid ...
If you have basic mechanical skils, tools and a lot of time I don't see reason why you can't do this alone and save 200GPB or more ... Do not forget change all gaskets with new ones!!! And if you pull out injector change teflon seal!!!

[th3_f15t]

Some good work going on here. I like it.