Leon Cupra R25

who.am.i said:

This is going to be one sick build.
Mate,u have to have some balls to do somethink like that
Friend was driven in 360hp mk5 gti,and he said wheelspin was name of the game
Cant wait to see,whats next with u.
Is it going to be daily or track?

vag familia

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Thank you, hopefully more of you will follow my path

My primary goal at the moment is to get all working and then go ahead with the AWD conversion.
I'm familiar with the wheelspin situations as I've been running a TTE420 with some nice power on the 2.0 TFSI engine that I've now removed.

The car will be driven anywhere, anytime but not on a daily basis.

Below is a dyno chart with the TTE420.

who.am.i said:

Mate,thats masive torque. For me is 400nm far enough at this time
Think that awd is right step to take.
What numbers are u looking for at new setup?

vag familia

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I'm going with a TTE500 turbo for this build, should see 530hp and more then 600Nm

Electrical wiring

I have an older generation of wiring for the PQ35 VAG platform (Yeti/Leon/A3/Golf...) . Thereby my current relays, BCM, Cluster utilizes completely different connectors and wiring.
Decided to avoid potential electrical issues and save some time by swapping the entire interior loom.

Ebay.de served me what I needed...






Received the wiring loom all nicely boxed up and weighting 19,3 Kg.
Nice to have features such as airbags, magnetic ride, Audio/GPS, Roadster, seats control where all deleted from the wiring loom and now I'm happily 7,2 Kg lighter.

I guess I can remove another 2 Kg but don't dare as the ECU might request it.
Will give it another go when I have it all installed in the car and can figure out what else can go.

Work in progress, you would imagine that network communication is fully utilized by now but apparently not...

who.am.i said:

Thats a big box of wires
Brakes will be ttrs all the way?

vag familia

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I fitted Porsche Cayenne front and rear brakes last summer that I will keep.
Noticed brake bias has been shifted against the rear due to the over-sized brakes. I plan to correct that behavior during this rebuild.

who.am.i said:

How big are cayene brakes?350mm?direct fit?did u fit it easy under the wheel?

vag familia

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Correct 350 mm front discs.
Not a direct fit on the Cupra aluminum hub, you need to cnc the hubs and calipers to fit it. Depending on wheel offset and design you might need spacers.

If you have the steel hub the front calipers should fit without modifications.

Wiring removal

Before I can integrate my modified TTRS wiring loom the interior trim and current wiring is been removed.

I have had several thoughts on what else I can delete during this phase, but I try to resist .
Deleting the heater/cooler pack would save me another 10Kg's, that would partly make up for the heavier 5 pot engine ...

Heat pack evaporator radiator delete

I've been running without a air-con radiator to optimize air flow and minimize the load on the engine on my former set up.
During this build the idea of removing the entire heat pack unit has passed my mind as it will save me weight. Loosing the heating feature has prevented me to proceed with the delete.
Thereby I decided on removing the internal air con evaporator radiator.

The genius inventor of this complex apparatuses should go to hell. The units consist of several server motors, plastic covers, screws, tubes, sensors and electrical wiring.
Anyway, I conquered with time and saved another 1,5 Kg for free.

Yes, not a lot of weight but removing several smal items will together add up.
Besides that the thought of knowing there is an item I could delete and not done so when the opportunity was there will bother me =)

TTE turbo ready

Today I picked up my TTE500 turbo from Kim at VagTuning.dk, my local friendly dealer!
I shipped away a unit that I bought in used good condition and received it back all cleaned and jacked up by the TTE team.

Custom coolant and oil lines sourced, to assist my connections to the 2.5NA block.

who.am.i said:

Mate,start putting engine together

vag familia

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I wish it was that easy =)

Swaybars, AWD version

As engine is out I have better access to things so I'm preparing for the future to come by changing the front swaybar. The front and rear swaybars are differently curved in-between the FWD and AWD vehicles.
But as earlier stated the full AWD conversion will be al later phase in the project.

I got hold of KW front 26mm and rear 23mm swaybars matching my current yellow 6 and 4 piston BBK .

Oil Cooler

The 2.5 TFSI engine is know to generate tremendous amounts of heat when pushed.
To prevent excessive heat I've decided to enhance the oil cooling with an external Mocal radiator set up.

The oem oil cooler is positioned on top of the oil filter housing. It's smal size-factor is limiting the heat exchange capacity and due to it's location the airflow is not optimal.
The Mocal radiator will be mounted in direct air flow and secure the proper cooling capacity.

• 15 row Oil Cooler
• Oil adapter plate, replacing the smal oil cooler on the oil filter housing
• Inline thermostat
• AN fittings
• XRP nylon braided

who.am.i said:

Parts are finaly getting together

vag familia

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At least it's getting closer =)

Hello Cupra R25

Passed a milestone in the project today, not the largest but morally important.

The modified TTRS loom has now been installed and partly integrated into the car. I was confident enough today that the installation was sufficient to allow me connect the battery.
Turned the key and got the nice cluster to needle sweep and light up, "Hello Cupra R25" !
Fetched my VCDS eagerly and got connected to check if I could communicate with the ECU and Gateway. No disappointment, there it was "2.5 TFSI"
There's a huge amount of wiring work left to get it all fully integrated with the switch-gear and other various features.

The cluster will get a facelift as I'll remove the "TTRS" badge inside later on =) . Working on a Cupra R25 badge but not ready with it yet.