Trouble getting my Fmic to fit. Help please!!

[reflexuk]

Can anyone help me with pics of a toyosports fmic fitted on a tdi pd130 please? I have a tdi kit
http://www.toyosports.co.uk/fmic-vw-golf-mk4-19-tdi-intercooler-kit-98-03--24499-1029-p.asp
and a couple of my pieces just have to be in the right place, but I'm strugling to pipe from the end of the u shaped piece on the fmic output to the long elbow with the map sensor in it which has a silicone elbow onto the EGR valve. I have the core running left to right, the opposite direction to a 1.8t. I will try to post pictures that will help explain

 

[reflexuk]

Hot side - from 1.8t pancake pipe. I'm 90% sure this is correct

https://picasaweb.google.com/lh/photo/HlbyBOzs2ZMRSK-7LQMG6w?feat=directlink

 

[reflexuk]

Here's how it must go along the front

https://picasaweb.google.com/lh/photo/JYa8aLH_xzNueRrGmrlOsQ?feat=directlink

 

[reflexuk]

This pipe has the map sensor fitted to the left side, it's also the only bit long enough to reach back to the egr valve elbow. It cant turn down because of the alternator and belt etc so it must turn the direction shown. 99.9% sure this is correct

https://picasaweb.google.com/lh/photo/Fdw6pEzPNE47Yh6RNNxeBg?feat=directlink

I know I need a sfs hose end or egr delete to connect, ordered, hopefully in the mail.

 

[reflexuk]

The pipework must run along the front of the oil filter and down to meet the end of the big U shaped piece that connects to the cold side of the ic core (not shown) That hard pipe on the P clip appears to be in the way though I think that's not difficult to reposition.

https://picasaweb.google.com/lh/photo/hluGXEpPLEl1dL_G5ulcug?feat=directlink

 

[reflexuk]

This is what I'm left to do it with, 3 elbows! All different!

https://picasaweb.google.com/lh/photo/KAySSDncrPGthZ5ZYffTIg?feat=directlink

2 of them are the same either way round though 1 is longer than the other.
1 of them has a long side and a very short side.


To recap, I have a horizontal coming right to left at the bottom of the bay on the right of the pic in the previous post and a horizontal at the top of the bay going to the egr valve.
Any 2 elbows together will make an s bend but none of the combinations I have left are long enough to bridge the gap and anyways I have 3 elbows!

What's gone wrong?

 

[reflexuk]

reading around it seems pipework issues are common with this kit, mostly folk work it out, and mostly on the 1.8t. can anyone help?

 

[reflexuk]

Today I had another look at the pipework kit to establish what might be missing. I did this by continuing to fit the pieces that were clearly in the right places to see what the 'gap' they would leave looked like. This is where I've got to now.

https://picasaweb.google.com/lh/photo/KSUTdmwdn_isvxOv7dAejg?feat=directlink

I used the larger two elbows, longest first, then the smaller one from the bottom up. I'm left with the elbow with the one short side, I am missing a straight piece of alloy pipe of around 300mm in length.

 

[reflexuk]

I found another problem as I continued to assemble. The map sensor clearly doesn't fit properly in the space provided for it. Has anyone found a solution to the problem of crating a good seal when it's fitted? I feel like glueing a rubber sleeve in there myself, though it might be difficult to find the right piece.

https://picasaweb.google.com/lh/photo/hz3HAFwKlIAv5SHrd1RJTQ?feat=directlink

 

[reflexuk]

Map sensor fitted today with an O ring made from an offcut of silicone hose. Bobbed it all together with a dab of the gasket compound in the pic, which smells a lot like silicone sealant and says it's good for upto 300C.

https://picasaweb.google.com/lh/photo/vlKSKRI3FmUq1s5NOM1ATw?feat=directlink

 

[reflexuk]

An SFS hose end was delivered today. Here it is fitted with my existing seal.

https://picasaweb.google.com/lh/photo/eaCkfTzRZKsBNp0-hILZPQ?feat=directlink

The 90deg silicone elbow in the hose kit is a diameter reducing that looks like it's intended to go onto a egr delete pipe. As a result I cut 20mm off the end of it and dipped the end in boiling water to get it over the alloy bayonet connector.

Now the map sensor is fitted it can be fitted to the car. Here is what I am left with. Despite shortening the reducing elbow the alloy pipe doesnt quite run straight fore/aft and now points towards the goddamn dipstick!

https://picasaweb.google.com/lh/photo/SgTv5-BAAzF4dxJaUCuBhg?feat=directlink

 

[reflexuk]

Next I turned my attention back to the hot side. As I have swapped to a 1.8t pancake pipe which doesn't have the clip system. Like forum member Madman, I squashed the bumps on the small end of the pipe. Squeeze carefully with a mole grip, it's quite easy to do and a silicone joiner clamps on there quite nicely.

https://picasaweb.google.com/lh/photo/m9TPfPn3D0XeXvKejsx9mw?feat=directlink

The straight hose easily goes over the pancake inlet but, the same 54-62mm size clamp wont fit round it so I need to get a bigger one.
Red hose ready to fit.

https://picasaweb.google.com/lh/photo/Gl7OLcStdiWVEKseHPvoiw?feat=directlink

I used a bit more of the gasket sealant stuff because that's the last place you want a boost leak.

 

[reflexuk]

Not been able to make any progress on the coldside piping so I decided to properly fix the IC core to the crash bar tonight, easily done with the supplied brackets, though I had to go to the bolts shop for M8 hardware to suit the supplied brackets.

https://picasaweb.google.com/lh/photo/PsQz85zQuTUvT5-vkvWiYg?feat=directlink

 

[reflexuk]

Tonight I am waiting delivery of a clamp onto the pancake pipe but I decided to finish fit the rest of the hotside pipework. I cut the corner of this bit of metal off so the pipe could butt up to the core.

https://picasaweb.google.com/lh/photo/MK4842Ry7GzQoUKaE4wNKA?feat=directlink#

I built it up with a dollop of the silicone sealant gasket to the joints for added security. It's hard to know when to stop tightening the clamps, I decided on a torque feel best described as 'quite tight but trying not to crush the pipe' lol. I keep reading about people having joints blow apart in use, also I don't have a boost leak tester so I'm trying to get it airtight first build. Fingers crossed.

 

[reflexuk]

Then I began the task of modifying the bumper to fit around the pipework. It's a case of cutting, refitting to see what's in the way cut and refit again, and again, and again until its done. I suspect I have it relatively easy here with a spacious LCR bumper. All the work takes place in the inner edges of the fog light apetures. I used a marker pen, a 4" grinder and a dremel tool. Here are the results, it looks like there will be room to refit the fog lamps. Yes, my bumper needs repainting.

https://picasaweb.google.com/lh/photo/kEKdx8q7Gc6-G-wnALT3pw?feat=directlink

https://picasaweb.google.com/lh/photo/lNkf2M_xbqjwxI8Itqln_Q?feat=directlink

https://picasaweb.google.com/lh/photo/R6bxCQwZ41QEBW6lWBCNEA?feat=directlink

 

[reflexuk]

Toyosports fmic - Eureka moment

Eureka! - report back later

 

[reflexuk]

HERE IT IS! Pipework conundrum solved.

The picture that everyone needs to fit this kit to their TDi

https://picasaweb.google.com/lh/photo/6V-05HPPLujOk34opRPCuQ?feat=directlink

If Toyosprts were just to put that one picture in their TDi kit then it would have been enough have saved me a 4 days of brain ache and lots of swearing.

I was looking around for the correct pipework route for days. Nobody could help me with advice but I found this vid on youtube which made me jump out of my seat. here's the key moment

https://picasaweb.google.com/lh/photo/jenYe6dx_LqpRu2hT_e_pg?feat=directlink