Aiming for the Masses - Uzi's 305BHP Mk4 Ibiza Cupra TDi (MODs & Pictures on 1st post

[Ibiza 130 tdi]

thats what i have planned. the allard pipe is 57mm so i need to order up the right silicone hose, do you know what size the aluminium pipework is where the 90 degree standard hose connect from to go to the egr?? i have a feeling it is the same but not sure??

Not sure tbh!!

remember our egr has the cooler so it is water cooled...can't remove that alltogether...if so how?

The older EGR's like the one that was on my PD130 53 plate are the older vacuum powered EGR's. On the newer cars, like 07 & 08 plate FR Pd130's for example, they are electricially powered and you cannont replace those with an EGR removal pipe.

You have a pipe going from the turbo/manifold to the EGR. You literally remove the EGR and that pipe all in one. Just put the blanking plate on the turbo and the straight pipe where the EGR was - leave it like that.

 

[uzi_cupra]

And then just leave the egr cooler there?

 

[Ibiza 130 tdi]

And then just leave the egr cooler there?

What does it look like??

 

[uzi_cupra]

Cylinder with 2 egr pipe connections, one side goes to manifold and the other goes to egr (the part that will be replaced with the race pipe)

 

[Ibiza 130 tdi]

Cylinder with 2 egr pipe connections, one side goes to manifold and the other goes to egr (the part that will be replaced with the race pipe)

You might have to find a pic - it's been so long since I did mine, seems forever since I sold my Ibiza now too so......

 

[georgebibizafr]

You might have to find a pic - it's been so long since I did mine, seems forever since I sold my Ibiza now too so......

Yours like mine is/was a pd130, as far as I know they don't have an egr cooler, just a bit of pipe from the exhaust manifold to the inlet manifold, egr valve, I know mine doesn't have a cooler, @ Uzi, your car has the pd150 engine ARL engine code, that does have an egr cooler, which as you described is a cylinder which cools the exhaust gas before it goes to the inlet manifold, To get rid off it very simply you can just put the blanking plate on the exhaust manifold before the cooler, then remove your egr assembly, and fit the allard pipe job done, to go further and loose a bit of weight and give you more space, you can remove the cooler alltogether by unbolting it from wherever it is bolted to, and joining the coolant hoses together which connect to it, this then removes the cooler completely.

 

[uzi_cupra]

getting my exhaust put on on thursday but still unsure if im gna go 3" or just 2.5", hopefully i will get the guy to make my downpipe from the same size of the exit diameter of my turbo which i think is 1.75" and step it up gradually to 2.5" or the 3" if i go with it...

 

[uzi_cupra]

ok so managed to get my downpipe put on, i got it custom made just the way i originally wanted, thanks to the guys at FUNKYPOWER in ayrshire!! would highly recommend them for custom exhausts as the equipment, tools and materials used are awesome! plus the guy is an amazing welder
in the end i decided to go for a 3". the way it was made was starting fromt he flange which is 1.75" and then a small piece of pipe at just under 2" which was then flared to 2.5" throught the bend and then another pipe flared from 2.5" to 2.75" with the 3" flexi and 3" through to the centre section. it is going back to get the rest made up but right now it has been stepped down at the centre section back to 2.25" for the rest of the standard exhaust. here are some pics

firstly here is my standard downpipe which i de-cated myself...

started from here...2" flared to 2.5" then to 2.75"

then with the 3" flexi

 

[uzi_cupra]

from here the rest of the 3" pipe

if anyone is looking for any work done the prices are great and work is as you see...the company is called funypower and are based in ayrshire/kilmarnock, for info contact Faz on 07941898310

 

[ScottHmk4]

nice mate, how does it sound

 

[MrNorma]

im sure i will now hear you passing by my work now. thats got to be loud?

 

[uzi_cupra]

nice mate, how does it sound

sounds like a loud petrol lol! its actually quite sweet normal driving and when you put the foot down you can hear the turbo whooshing! i went through the clyde tunnel yesterday and it sounded unreal for a diesel!

 

[uzi_cupra]

im sure i will now hear you passing by my work now. thats got to be loud?

lol ye no doubt we shoud be having a meet soon so will show you what its like if you come

 

[ScottHmk4]

lol ye no doubt we shoud be having a meet soon so will show you what its like if you come

http://www.seatcupra.net/forums/showthread.php?t=269967

 

[Ibiza 130 tdi]

I'm not having a go or critising, but do you NEED a 3 inch pipe? I know if you have too big a pipe you will actually lose back pressure and therefore power. Even my R32 only have 2.5 inch bore. So was my Ibiza.

Are there any advantages? I'd have though manifold modifications would be worthwhile as they're tiny outlets on the Ibiza.

 

[uzi_cupra]

I'm not having a go or critising, but do you NEED a 3 inch pipe? I know if you have too big a pipe you will actually lose back pressure and therefore power. Even my R32 only have 2.5 inch bore. So was my Ibiza.

Are there any advantages? I'd have though manifold modifications would be worthwhile as they're tiny outlets on the Ibiza.

Yea I went through the pros and cons and the reason I went for 3" is because I'm going bigger turbo which i kept quiet lol.I'm getting the gtb2260 from a 3.0tdi,which holds boost electrically but I can change that to hold boost through the actuator. The boost running through the turbo will be round about 2.2bar so that's why I went 3" and all I will need to change is the flange on the downpipe for the new turbo.
You are right for this turbo even though hybrid won't be that beneficial but will give better low down power. As long as the downpipe is stepped up properly the set up will work efficiently,even when people buy the 2.5" miltek it is not that efficient because at the exhaust exit the flow will be tubular....which is something i did not want at all.

 

[Ibiza 130 tdi]

Yea I went through the pros and cons and the reason I went for 3" is because I'm going bigger turbo which i kept quiet lol.I'm getting the gtb2260 from a 3.0tdi,which holds boost electrically but I can change that to hold boost through the actuator. The boost running through the turbo will be round about 2.2bar so that's why I went 3" and all I will need to change is the flange on the downpipe for the new turbo.
You are right for this turbo even though hybrid won't be that beneficial but will give better low down power. As long as the downpipe is stepped up properly the set up will work efficiently,even when people buy the 2.5" miltek it is not that efficient because at the exhaust exit the flow will be tubular....which is something i did not want at all.

Good answer

 

[uzi_cupra]

Good answer

Lol cheers!glad it made sense

 

[uzi_cupra]

car is going in for major work in the next week or so for the following
full re-spray (will put what colour up soon)
engine will be out for a rebuild
audi 3.0l tdi big turbo
Race 783 nozzles
sachs sintered paddle clutch
Limited Slip Diff
uprated camshaft and stronger head bolts
bigger turbo intake pipe
uprated MAF & MAP sensors and maybe BMC induction

will be looking at having less restriction from flow going from intercooler to intake
spending quality time on her for the next 6-8 weeks

 

[gulzar]