Thread: TDI VNT Turbo Upgrade +++

Test fitting the inner wing on the turbo side and the turbo outlet is throwing up an issue. It exits ~1cm further out to the wing, forward to intercooler and further down to the chassis rail. Not much but the exit was very tight on the old turbo with no room to spare. So the silicone bend gets squished in by the wing and the silicone bend forced over its natural radius by the chassis rail. No good!

Little choice but to cut the inner wing to make room for the bend, the original profile of the wing will be restored by a rubber mudguard that I will cut to shape and rivet in place.



As for the silicone bend not quite making it over the chassis rail, Im not sure what to do there just yet. In the pic below the bend has been forced ontop of the rail, causing it to crush in on itself and rest on the brake pipe.



Finally the bottom intercooler connector is not ideally aligned, I would like to rotate it. The pipe from turbo to intercooler should run parallel to the chassis rail, leaving more space for the turbo inlet pipe that runs above it. As it is they are pressed on each other.

Can you loosen the bolts on the compressor housing of the turbo and rotate it so the outlet drops down behind the chassis rail?

VNT i played with for my 300TDI could do this at will as it is all symetrical inside.

Also, is the intercooler stock?

A 300tdi intercooler is about the same size and the inlet has less of a bend in it, pick one up pretty cheap. Im not sure how it will mesh up with the radiator cowling tho.

I have cut a a couple of cm off the end of the silicone bend which has brought it back in a mm above the brake pipe. So I am tempted to leave it in the configuration shown, and see how it goes on the road.

Otherwise, for a better fit, I will need to take the intercooler to get modified and remove the turbo to try and clock the housing or get a tight bend welded onto the housing. Im growing impatient so I'll try and dodge those jobs for now.

The bolts on the compressor housing are not evenly spaced so whilst I may be able to clock it, it might not provide the orientation I need. I will have another look at it next time in.

Cheers.

Originally Posted by SSmith

Also, is the intercooler stock?

A 300tdi intercooler is about the same size and the inlet has less of a bend in it, pick one up pretty cheap. Im not sure how it will mesh up with the radiator cowling tho.

The intercooler is a double core from allisport so I would look for someone to rotate the inlet. No rad cowling on this motor. Electric fan.

Originally Posted by manic

The bolts on the compressor housing are not evenly spaced so whilst I may be able to clock it, it might not provide the orientation I need. I will have another look at it next time in.

If it is the same as the ones ive played with, the bolts just pinch down on a lip on the core, so they rotate freely with the compressor housing and you can tighten it up in any alignment you want.

But, if it is working for now then only need to look at it if it is rubbing.

Originally Posted by manic

The intercooler is a double core from allisport so I would look for someone to rotate the inlet. No rad cowling on this motor. Electric fan.

Bit of a bigger task then

Back to the guys who welded the custom intake?