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W13 JAL - '04 Leon Cupra R - GT30 coming soon!! (Page6)
- Thread starter John Lindsay
- Start date
Yah Man!
Will get it fitted up for pipework soonish, the freak decision to book a holiday today might cause progress to slow up a bit for a while!
Got a charity Rolling Road day on the 4th May though and it would be nice to have the intercooler fitted for then so we'll see how things pan out.
Will get it fitted up for pipework soonish, the freak decision to book a holiday today might cause progress to slow up a bit for a while!
Got a charity Rolling Road day on the 4th May though and it would be nice to have the intercooler fitted for then so we'll see how things pan out.
With the distinct lack of storage space' in the Leon I picked up this genuine VW armrest.
Needs a wee bit of modification but fits a treat.
Needs a wee bit of modification but fits a treat.
Intercooler pipework ordered up. Hopefully fitting on Tuesday night!
Picked this up today from Jim at racediafnostics.com Great piece of kit, Jim is a great guy too, highly recommended!
Picked this up today from Jim at racediafnostics.com Great piece of kit, Jim is a great guy too, highly recommended!
Yeah they're £225 worth it though!
Cheers, yeah pipework is hopefully arriving today, so fitting tomorrow night with a bit of luck.
So... Finally time for an update.
Intercooler is now on!
When mocking it up we decided it would be better if the pipes coming off the intercooler were kicked back at 45 degrees so I got some welded on by a local place.
Original intercoolers and pipe work removed, some of the metal framework needed slightly modified to let the intercooler sit back nearer the AC Rad:
New Alloy support brackets:
All fitted up, the good thing is that no modification of the crash bar or other supports was necessary:
Bumper re-fitted with minimal modifications also, had considered painting the whole intercooler black to be more discreet but now I'm glad I didn't, it's not in your face at all, but I think I will paint the alloy pipes as they're a bit too visible through the fog light grills.
Still getting a persistent 17705 - Pressure Drop between Turbo and Throttle Body (check DV) so going for a smoke test hopefully after work tomorrow to hopefully rule it out because I don't see how there can still be any leaks with all new pipework. From what I'm lead to believe its most likely to be a bug in the software, which I don't really understand either but its going for stage 2 mapping on Saturday so fingers crossed it'll be tip top after that.
Also getting a fault code for pre cat lambda sensor so I think I'll get one of them tomorrow.
John
Intercooler is now on!
When mocking it up we decided it would be better if the pipes coming off the intercooler were kicked back at 45 degrees so I got some welded on by a local place.
Original intercoolers and pipe work removed, some of the metal framework needed slightly modified to let the intercooler sit back nearer the AC Rad:
New Alloy support brackets:
All fitted up, the good thing is that no modification of the crash bar or other supports was necessary:
Bumper re-fitted with minimal modifications also, had considered painting the whole intercooler black to be more discreet but now I'm glad I didn't, it's not in your face at all, but I think I will paint the alloy pipes as they're a bit too visible through the fog light grills.
Still getting a persistent 17705 - Pressure Drop between Turbo and Throttle Body (check DV) so going for a smoke test hopefully after work tomorrow to hopefully rule it out because I don't see how there can still be any leaks with all new pipework. From what I'm lead to believe its most likely to be a bug in the software, which I don't really understand either but its going for stage 2 mapping on Saturday so fingers crossed it'll be tip top after that.
Also getting a fault code for pre cat lambda sensor so I think I'll get one of them tomorrow.
John
Superb work on the cooler buddy!!
With regards to that code, check the main hoses (big and small) mainly around the DV, n75 and also check the hose which sits on top of the turbo to the charge pipe as I recently found out how badly I destroyed mine. Other than that it can be software related as most found in the early stages. Most maps have fixed this bug so hopefully once the checks and the new map are on you should be code free
With regards to that code, check the main hoses (big and small) mainly around the DV, n75 and also check the hose which sits on top of the turbo to the charge pipe as I recently found out how badly I destroyed mine. Other than that it can be software related as most found in the early stages. Most maps have fixed this bug so hopefully once the checks and the new map are on you should be code free
I wish I had an LCR like that
If you'd get your finger out and fit some parts instead of hoarding them then you'd be pretty close!
With the distinct lack of storage space' in the Leon I picked up this genuine VW armrest.
Needs a wee bit of modification but fits a treat.
Can you elaborate on the armrest .
Where did you buy it? Do you have a part number ? Also what was involved in installing it?
The car look brilliant btw, great mods.
It's a Mk4 Golf arm rest, part number I'm not sure of.
Modification required was cutting an opening in the centre console, the little recess between the handbrake and rear ashtray basically needs opened entirely and then the shroud of the arm rest needs trimmed until it will go far enough into the centre console as meet with the bracket down below.
Anything else just ask away!
Modification required was cutting an opening in the centre console, the little recess between the handbrake and rear ashtray basically needs opened entirely and then the shroud of the arm rest needs trimmed until it will go far enough into the centre console as meet with the bracket down below.
Anything else just ask away!
Had a few folk asking for more info on the intercooler.
The intercooler I fitted is this one: http://www.toyosports.co.uk/fmic-ffront-mount-turbo-intercooler-type-r-550x225x64mm-6699-955-p.asp
Additional pipe work was bought from Auto Silicone Hoses, note this image shows enough pipework for 2 cars, so if you're doing only one, then half the quantities.
Apologies if the image quality isn't the best, it looks fuzzy on my phone:
2 of the 45° alloy bends were cut slightly shorter and welded directly to the intercooler:
Once the bumper is off you'll see a piece of ducting, held on by three screws, I removed that, then cut right along the front of that section to remove the brackets for those three screws, and also the small lip. Some of the plastic shrouding also needed trimmed.
Then the intercooler was mocked up and held in place, we made some brackets for the bottom from a nice sheet of 6mm alloy and fixed it to the lower lip of the radiator surround with self tappers, at the top a piece of perforated strip was used, and bolted down through from the top of the crash bar. The only modification to the crash bar was drilling those 2 holes.
I used a 90° alloy bend to come out of the silicone hose from the charge pipe, then linked it to the intercooler with a 45° silicone bend. The 90° alloy one needed cut shorter on the charge pipe side to allow it to sit further in towards the centre of the car. Then, since I had cut off the factory swaging I recreated it using this professional piece of equipment:
It's a plain washer, and an exhaust clamp welded to a pair of vice grips, simple but effective:
Testing on an offcut - factory swage on the right, mine on the left:
On the passenger side of the car a 90° silicone elbow was fitted to the map sensor pipe and connected to another 45° elbow with a 50mm alloy joiner, then connected to the intercooler.
All the silicone hoses were cut slightly shorter to get the fitment right.
Although the fog lamps are in place they are not functional. I cut the lenses from the front of mine and fixed them in place with sikaflex. I wasn't particularly bothered about losing their functionality, because I think people who drive about with their fogs on are idiots, and I've never noticed a great benefit using them in fog anyway. However, I wanted it to look standard at the front.
However, if you wanted them to work, then universal fog light kits are available on eBay, which are quite compact, there is space behind the grilles to accommodate a fog lamp, just not enough for the massive plastic enclosure that is fitted as standard.
Total cost for one car roughly £220.
Hopefully this is some assistance to some people =]
The intercooler I fitted is this one: http://www.toyosports.co.uk/fmic-ffront-mount-turbo-intercooler-type-r-550x225x64mm-6699-955-p.asp
Additional pipe work was bought from Auto Silicone Hoses, note this image shows enough pipework for 2 cars, so if you're doing only one, then half the quantities.
Apologies if the image quality isn't the best, it looks fuzzy on my phone:
2 of the 45° alloy bends were cut slightly shorter and welded directly to the intercooler:
Once the bumper is off you'll see a piece of ducting, held on by three screws, I removed that, then cut right along the front of that section to remove the brackets for those three screws, and also the small lip. Some of the plastic shrouding also needed trimmed.
Then the intercooler was mocked up and held in place, we made some brackets for the bottom from a nice sheet of 6mm alloy and fixed it to the lower lip of the radiator surround with self tappers, at the top a piece of perforated strip was used, and bolted down through from the top of the crash bar. The only modification to the crash bar was drilling those 2 holes.
I used a 90° alloy bend to come out of the silicone hose from the charge pipe, then linked it to the intercooler with a 45° silicone bend. The 90° alloy one needed cut shorter on the charge pipe side to allow it to sit further in towards the centre of the car. Then, since I had cut off the factory swaging I recreated it using this professional piece of equipment:
It's a plain washer, and an exhaust clamp welded to a pair of vice grips, simple but effective:
Testing on an offcut - factory swage on the right, mine on the left:
On the passenger side of the car a 90° silicone elbow was fitted to the map sensor pipe and connected to another 45° elbow with a 50mm alloy joiner, then connected to the intercooler.
All the silicone hoses were cut slightly shorter to get the fitment right.
Although the fog lamps are in place they are not functional. I cut the lenses from the front of mine and fixed them in place with sikaflex. I wasn't particularly bothered about losing their functionality, because I think people who drive about with their fogs on are idiots, and I've never noticed a great benefit using them in fog anyway. However, I wanted it to look standard at the front.
However, if you wanted them to work, then universal fog light kits are available on eBay, which are quite compact, there is space behind the grilles to accommodate a fog lamp, just not enough for the massive plastic enclosure that is fitted as standard.
Total cost for one car roughly £220.
Hopefully this is some assistance to some people =]
Last edited:
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