Crono Yellow 2007 Ibiza Cupra TDI - THS Intercooler & more 21.02.13

[ChrisBoom]

Rather bored tonight, so thought I'd make a thread on my cupra.

Bought it almost a year ago, went all the way to Bristol for it, about 1200 miles:

Did nothing to it for months, just kept it clean. Front bumper was being torn apart by stone chips though!

Fitted a forge boost hose which promptly burst:

Winter was coming, so bought this:

And put this in the garage for the winter:

Which now looks like:

Got these to go on:

And these:

Put the bumper, bonnet and boot badge all away to get sprayed. They made a fantastic job of it, need to get pics but the car and bumper etc is all at my parents house.

Work to be done before the end of March:

• Fit FK Silverlines
• New discs and pads on front
• Refit bumper, bonnet etc
• Clean up Intercooler, all boost pipes etc and refit
• Fit powerflex engine mount
• Few coats of Banana Armor

Shall get more pics next time I'm at the garage, aside from the work listed I'd like a Whiteline RARB, but plenty time for that.

Also got a load of genuine new Seat parts for it, all bolts and top-mounts etc involved in the suspension, new front plate, new center caps, LED bulbs, few other small bits.

Need to get rid of the over spray on the headlight too, previous owner must have had the bumper sprayed on the car.

 

[ChrisBoom]

RR Graph:

 

[Cupratje]

Great looking car!
Its not the first Forge hose that i see that burst...

 

[Guncha]

Great car! Good luck with mods

 

[ChrisBoom]

Cheers for the comments. On the hunt for a Whiteline RARB now.

 

[ChrisBoom]

Whiteline RARB ordered, got a great deal from Awesome (http://www.awesomegti.com/)

Shall get pics soon.

 

[ChrisBoom]

Well I finally got some time to go up and work on the car. Unfortunately, a few problems!

Firstly, the garage roof has been leaking, water has been running directly onto the car. I had the windows left open a wee bit to let air circulate, but mould decided to visit

Fortunatly it cleaned off very easily! No smells etc, so not too bad.

Next problem - The intercoolers on these are renowned for leaking, so I thought Id check mine, sure enough, its leaking;

Not sure if it can be repaired? Ordered a THS Intercooler from AwesomeGTI, bit bigger and the end caps are welded rather than crimped, so shouldn't leak! Shall sell the old one as spares.

Sorting the intercooler etc took up a good bit of my day, but I managed to get the rear up in the air, ripped the old suspension off, fitted the coilovers and RARB:

Currently sitting like this, still got another 8 threads of adjustment, might go lower yet, see what like it is once it settles;

Used brand new nuts & bolts throughout the renewal of the suspension, will be the same for the front when I get round to doing it!

New centre caps, old ones are rough:

Quickly built up the fronts to see how they go together, shall give them a good coat of copper grease before I put them together properly. Brand new top mounts & bearings too.

Got a new front plate for the bumper, still need to fit the splitter;

Few jobs to do yet;

1. Discs & Pads on the front
2. Front coilovers/droplinks
3. Engine mount bush
4. Fit new intercooler
5. A serious cleaning session

 

[ChrisBoom]

Intercooler turned up at the parents house on Monday, so went up on Tuesday to put it all back together.

New vs old:

Fitted:

Also fitted the powerflex engine mount:

At this point I was meant to start fitting the discs and pads, but my good old halfords punch snapped on the first use! That'll be getting returned anyway. Brakes will get done soon.

Then fitted the bonnet & bumper back on, also changed sidelights, number plate and interior bulbs with LED's:

Today was a 7 hour cleaning session, wheels off job. While the wheels were off, I lowered the coilovers a bit more

Didn't take any pictures during the cleaning, but here's the end results:

Used autosmart brisk to remove all the mould etc inside, worked great! Better than ever:

Shall be getting new floor mats though as they are pretty howling with mould :facepalm:

Still waiting on the boot lock back from the painters, they lost the first one should have it this weekend though. It's getting painted the same colour as the bumper lip

Also stumbled upon another problem - heater fans are not working. Fuses etc are all ok - I'm hoping it's just the motor needs a good thump, it was fine before it was parked up!

Jobs still to be done before it's back on the road:

1. Front brakes
2. Fit washer jets
3. Fix heaters
4. Tax

 

[ChrisBoom]

Boot lock is ready, shall collect it and fit on Tuesday. Shall also get the rest of the bits finished off and get it insured.

 

[ChrisBoom]

Well finally got my boot lock back from the sprayers;

So got it fitted:

Next was the brakes. What an utter, utter **** of a job. Passenger side was fine, pins came out no problem, discs & pads were changed easy.

However, drivers side was a different story. Pins were completely seized, hours of hammering did nothing. Eventually after much grinding, hammering and drilling, I got them out. Had to remove the caliper so brakes needed bled after.

Also raised the coilovers a bit at the front as they were rubbing on the front.

Got a serious task next, heater motor has packed in somehow. Was fine before it was parked up! Put 12v to it today and nothing, so motor needs replaced. Haynes etc all say dash out to replace it

 

[fuzzy232]

cars looks good, I also got that THS intercooler as my Seat sport did exactly the same as yours!

 

[ChrisBoom]

Aye I thought it was the boost pipes that were leaking so bought all new seals etc.. Good job I checked the Seat Sport one when I was cleaning it!

 

[MiiTCH-AROSA]

My intercooler is leaking too

 

[Cos]

Car looks really nice mate!

I like the look of that intercooler as well. Is it much bigger than the SS?

How was fitting? same brackets/pipe work? Any trimming?

 

[fuzzy232]

Thicker stronger cores and end tanks. It fits exactly the same as the ss one.

 

[ChrisBoom]

As fuzzy says, direct replacement for the original. Seems far better quality.

 

[MiiTCH-AROSA]

I've just put one on mine it's far better quality looks better behind the bumper too although I think I need a new turbo