TFSI Swap

[Stvxrt]

Here’s a picture of the somewhat final result. Unfortunately I don’t currently have any pictures which show the amazing wiring work that Andy has done but you’ll just have to believe me until I can get some pics up

[Stvxrt]

[Stvxrt]

Unfortunately it wasn’t all sunshine and rainbows from the weekend when it was wired but we learn from our mistakes right?
when I refitted the brake master cylinder I failed to line up the rod in the servo with the piston on the master and when we pushed my van down the ramps off the trailer I had 0 brakes, absolutely nothing. My reaction time with the hand brake also wasn’t quick enough to stop my van rolling into another car. Here’s the damage

[Stvxrt]

The TFSI fun doesn’t stop once the engine is in and running though.
I picked up an upgraded high pressure fuel pump and a Revo Intake from AKS tuning in the Black Friday sales. Highly recommend them, always super quick delivery, reasonable prices and excellent customer service.

[Stvxrt]

I’m not going to go into too much detail on fitting the HPFP, there’s plenty of guides online which show clearly how it’s done, it’s a pretty simple job even for a diyer like myself. When fitting the bump I also drilled out the fuel feed fitting on the pump to 5mm. This is a common mod on the tfsi engines, no performance gains have been proven but many people seem to recommend doing it just to allow the fuel to flow to the pump a little easier.
The revo intake is a doddle to fit, fits extremely well in the caddy engine bay. The air filter sits nicely behind the headlight with no clearance issues at all
The engine cover must be removed to fit the revo intake so I’m keeping an eye out for a second hand TTS engine cover to tidy things up but I think I may just have to bite the bullet and fork out for a brand new one from AKS tuning.

[Stvxrt]

Andy from Overboost has amazed me once again, when he was here wiring up the van he downloaded all the data from my instrument cluster so that he could source me some tfsi clocks, code them to my van and post them to me so they would work plug and play. I received the clocks along with a second key for the van and they couldn’t have been easier to fit, a true plug and play service. I really can’t recommend this guy enough.

[Stvxrt]

Next up was an intercooler upgrade. I opted for the full alloy audi s3 cooler. Nissens p/n 96420. This was extremely straight forward to fit and is highly recommended when running a k03 turbo as bigger coolers are known the kill the low end torque which the smaller turbo has to offer. The cooler fitted just like the standard caddy one, all that I had to do was carefully cut the bayonet fittings off the 2 lower boost hoses with a junior hacksaw so that they could be clamped onto the cooler with hose clamps. the screws that hold the radiator to the intercooler had to be replaced for some m6x16 Allen headed bolts since I was now bolting into alloy rather than screwing into plastic.

[Stvxrt]

Got a slight issue with the caddy at the moment, doesn’t seem to be making as much power as it should. I’ve been trying to work out in my head what’s wrong with it, I’ve changed the diverter valve but the old one was still intact so it’s not that. I decided to take the exhaust off from the decat back and give the van a run and straight away it felt much much faster so I believe it’s because I’m still running the stock caddy catback. So a custom catback exhaust is next on my list of things to do.

[ToiletTFSI]

Unfortunately it wasn’t all sunshine and rainbows from the weekend when it was wired but we learn from our mistakes right?
when I refitted the brake master cylinder I failed to line up the rod in the servo with the piston on the master and when we pushed my van down the ramps off the trailer I had 0 brakes, absolutely nothing. My reaction time with the hand brake also wasn’t quick enough to stop my van rolling into another car. Here’s the damage

i have a good condition mk4 rear drivers door if your replacing

[Stvxrt]

i have a good condition mk4 rear drivers door if your replacing

Thank you, it’s already under control though. Got two replacement doors and it’s at the bodyshop just now. Getting a good freshen up at the same time


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[pippo]

Great work so far!

[The_White_Van_Man]

Great work, I love the colour.

Could I ask how much it cost for the wiring to be done for you? I think the 1.6 in mine is dead so I'm looking at TFSI swapping it. The mechanicals don't phase me, but the wiring is a bit daunting. So the idea of getting someone to wire it all up for me is quite appealing.