Thread: IHI Roller bearing turbo

Here are a few pictures of the turbo kit as supplied by Jabba sport:


The turbine side of the exhaust. You can see the turbine and also the wastegate.

This is a pic of the whole kit as supplied. Consists of (from left to right, top to bottom):

• intercooler boost pipe
• Coolant feed pipe
• Jabbasport cast exhaust manifold
• Coolant return pipe
• VF-34 Roller bearing type turbo (as used on Scooby WRX STI)
• Cast exhaust housing

I also got Bosch green top 440cc injectors and 4 bar FPR. (Which should actually not be used for the 1.8T due to the spray pattern. Go for genesis 415cc instead)



The inlet side of the turbo. A view of the inlet, outlet, actuator.

I've done the install...finished it on friday. All i can say is that it was MUCH harder than i thought it would be. Really is not a straight swap! The OE turbo and manifold .etc came out within 3 hours... really was a piece of p1ss to do and had no problems with seized bolts or anything so i was lucky there.

The fun came when installing the new one!

First problem i came accoss was getting the turbo into the car! it JUST fit in! really was a tight fit to get it behind the engine! Once in, there is plenty of room to work so its not a problem there.

After getting the turbo in, i then bolted up the manifold to the head which was a bit awkward as the bolts are in really tight spots, but wasnt really a huge problem, juast a bit irritating when it takes 20 minutes to do up one bolt!

After doing this, i start to connect up the oil feed pipe. This proves to be the hardest part of the install! Basically, it wont fit! ITs impossible. When you put it on the turbo, then try and fit the turbo onto the manifold, the turbo sits about 5-6mm away from where it needs to be which causes a big problem! After trying to bend the oil line and generally ;1ssing about with it for 2 hours i get annoyes and give up! Went round to a hydraulic specialist locally and got him to make up a flexible oil line for me with the correct banjo ends... cos an extra £20 but solved my problem! So i get home and go to install the line. I had left the OE one attached to the turbo so i go to unscrew the banjo bolt with the wrench, but after a 1/4 turn of the wrench it goes all loose...reach down and pull the bolt up and to my horror, the bolt had snapped and left the thread in the turbo [img]/ubbthreads/images/graemlins/shocked.gif[/img] I was NOT happy! I had to remove the manifold, remove the turbo take it to an engineering firm locally adn get them to remove the remaining thread whilst making sure not to leave any remains of metal in the hole! Luckily it came out ok as it wasnt tight in (VERY LUCKY INDEED!). Once i got home again it was too late to do anything so i gave up for the day! Being in such a bad mood, its probably a good thing i didnt continue!

So friday was a very productive day! managed to refit the manifold, connect up all the fluid line, mount the turbo on the manifold, finish connecting up the intercooler. All that remains for me to do is connect the TT intake pipe, with all the hoses that come off of that, reconnect up the intercooler pipework, finish off the bumper and refit it, drop it off the axle stands and give it a clean, ready to go to AmD next week for the remap and exhaust downpipe fabrication. By next thursday, it will be ready to roll and be one quick car! Oh i SOOO cant wait! a whole 9 days is going to be agony!

Will report back with more pics in a few days when i get myself together!

Cheers

Rich

Sorry to hear about the bolt.. and you were definatly right to walk away and start again another day .. hope the rest of it goes smoothly [img]/ubbthreads/images/graemlins/smile.gif[/img]

I think you should give up and give me the parts to test [img]/ubbthreads/images/graemlins/grin.gif[/img]


On a serious note but, I know what you mean about walking away and coming back when you have cooled down..........but at the same time you want to get it done quickly so you can drive it

Rich,

Didn't you take any picks mid install for us sad bods on here!!

If yes............get erm up!

[ QUOTE ]
HTC said:
Most annoying when things don't go to plan! :-(

So have you brought the oil feed pipe issue up with Jabbasport. Perhaps they mistakenly sent you the wrong part?

[/ QUOTE ]

Very annoying indeed!

Jabba APPARENTLY use the original oil feed and return pipework! Return fits fine but is a bast*rd to fit, but the feed pipe doesnt fit at all! Not yet brought it up with Jabba but will do when its all done.

Rich

[ QUOTE ]
S3 Mike said:
I think you should give up and give me the parts to test [img]/ubbthreads/images/graemlins/grin.gif[/img]


On a serious note but, I know what you mean about walking away and coming back when you have cooled down..........but at the same time you want to get it done quickly so you can drive it

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hahahaha.. likely!

After doing it on my A3, there is no way I would attempt it on an S3 simply because there is NO room at the bottom of the engine due to the transfer box...there are some parts in the process that can only be done from under the car which would make it near impossible without having rubber arms!

Rich

[ QUOTE ]
jayfrst said:
Rich,

Didn't you take any picks mid install for us sad bods on here!!

If yes............get erm up!



[/ QUOTE ]

I didnt im afraid...however, they really wouldnt be too interesting as it would have been open space behind the engine. I will take a few pics tonight of the turbo installed.

The problem im having at the moment is getting the TIP onto the turbo inlet... this is a real basta*d! The TIP is smaller than the intake you see so its a tight fit but it DOES go on...tried before installing everything, but theres so little room to get anything under the hose to pull it over the inlet. Very frustrating! hopefully the weather will be better tonight so i can do it then. Have to drop the turbo off the manifold to do it too... Only 3 bolts tho and take about 1 minute to do.

Rich

[ QUOTE ]
RichA3Turbo said:
Removing the driveshat WOULD make things much easier as you could probably drop the turbo out and putthe new one in from the bottom. Its gets in the way a bit especially for connecting up the oil return pipe (this was a f****** c*** of a job!!! had to put bolt in socket, put that through the bolt hole, put the gasket on that, then manoeuver it into place.

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So true about the driveshaft, and considered doing it when changing my turbo, but considering only a month before i had replaced one CV joint and both boots...I was not in the mood to be taking it off again!

And the oil pipes are just a complete pain in the arse, no room anywhere to get at the feckers! [img]/ubbthreads/images/graemlins/burningmad.gif[/img]

At least the end result will be worth all the foul mouthing....by the way how much skin are you knuckles down on now?

[ QUOTE ]
Gambba said:
At least the end result will be worth all the foul mouthing....by the way how much skin are you knuckles down on now?

[/ QUOTE ]

Most definately!

Well on knuckle on my right hand i reckon hit tendon! lol. Put ALOT of force on a wrench (probably most of my body weight) and it suddenly gave way and my fist went full pelt into tarmac! OUCH! thats along with lots of little cuts, grazes, and scratched to [censored] underside of arms! Well atleast i can say "this scar is for this and this scar is for that" lol

Rich [img]/ubbthreads/images/graemlins/lol.gif[/img]

Yeah, it will be interesting to compare AMD's mapping as aposed to one of Jabba's maps.

Hey Rich you're certainly gonna have a hell of a lot of fun with that upgrade.

I bet you're like a kid before Christmas waiting to get this finished - must be driving you crazy [img]/ubbthreads/images/graemlins/crazy.gif[/img] [img]/ubbthreads/images/graemlins/crazy.gif[/img]

[ QUOTE ]
RichA3Turbo said:
Put ALOT of force on a wrench (probably most of my body weight) and it suddenly gave way

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Crikey! It must have been a difficult job with ALL your body weight [snigger] [img]/ubbthreads/images/graemlins/tongue.gif[/img]

My preferred method to remove stubbord audi bolts is to use a 18" breaker bar attached to a 4 foot scaffold pole and then balance the combined weight of me and Glen on the end of it. A not insonsiderable force. I found the use of a Glen most helpful for such bolts and recommend you rent one out for the next job Rich!! [img]/ubbthreads/images/graemlins/smile_smoking.gif[/img]

Its easier to shock bolts free usually. Impact wrenches work well. I have a snapon cordless one which hasn't let me down yet.

HTC - the bolts in question were out of reach of the impact wrench sadly [img]/ubbthreads/images/graemlins/frown.gif[/img]

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David R said:
HTC - the bolts in question were out of reach of the impact wrench sadly [img]/ubbthreads/images/graemlins/frown.gif[/img]

[/ QUOTE ]

same

WOW - that will be one quick car. I bet you respect it more with doing the work yourself too - no more premature shutdowns i bet, full two minute rundown after every run?

Makes me wonder, has anyone fitted a turbo timer and will they work with the audi alarm system/ key code thing?

[ QUOTE ]
nervus said:
WOW - that will be one quick car. I bet you respect it more with doing the work yourself too - no more premature shutdowns i bet, full two minute rundown after every run?

Makes me wonder, has anyone fitted a turbo timer and will they work with the audi alarm system/ key code thing?

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Definately... I look after the car well anyway...now even more so. It will need it! In theory because its not running at its limit like the K03, it should run cooler which is always good. With the FMIC too it should be excellent. But yeah full cool downs for brakes and turbo.

Rich

[ QUOTE ]
nervus said:

Reminds me of fitting new grips to my BMX!

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[img]/ubbthreads/images/graemlins/laugh_roll.gif[/img] Classic!

[ QUOTE ]
nervus said:
Oh well, try heating it in hot/boiling water as it will stretch and become more deformable! It eill defo help!

Reminds me of fitting new grips to my BMX!

[/ QUOTE ]

haha yeah!

Yep will soak it in boiling water for 15 minutes or so and get it nice and soft...hopefully i can manage it without removing the turbo... AGAIN!!! Tis been on and off the manifold about 5 times [img]/ubbthreads/images/graemlins/crazy.gif[/img]

Rich

[ QUOTE ]
nervus said:
Oh well, try heating it in hot/boiling water as it will stretch and become more deformable! It eill defo help!

Reminds me of fitting new grips to my BMX!

[/ QUOTE ]

Thing is, aren't Samco hoses designed to prevent just that? [img]/ubbthreads/images/graemlins/frown.gif[/img]

[img]/ubbthreads/images/graemlins/beerchug.gif[/img]

[ QUOTE ]
Drill said:
[ QUOTE ]
nervus said:
Oh well, try heating it in hot/boiling water as it will stretch and become more deformable! It eill defo help!

Reminds me of fitting new grips to my BMX!

[/ QUOTE ]

Thing is, aren't Samco hoses designed to prevent just that? [img]/ubbthreads/images/graemlins/frown.gif[/img]

[img]/ubbthreads/images/graemlins/beerchug.gif[/img]

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No.. they can actually stretch quite a bit... Waht im doing is forcing in a metal sleeve to open it out and then this will open the end up, and then i just have to force it onto the turbo. Sounds easy.. i know it wont be!

Rich

So the TT pipe was too large then? By how much if so? Was trying to figure out a way of mounting an S3 or TT intake pipe on to a K03 [img]/ubbthreads/images/graemlins/angel.gif[/img] [img]/ubbthreads/images/graemlins/grin.gif[/img]

Anyway, good luck [img]/ubbthreads/images/graemlins/beerchug.gif[/img]

[ QUOTE ]
Drill said:
So the TT pipe was too large then? By how much if so? Was trying to figure out a way of mounting an S3 or TT intake pipe on to a K03 [img]/ubbthreads/images/graemlins/angel.gif[/img] [img]/ubbthreads/images/graemlins/grin.gif[/img]

Anyway, good luck [img]/ubbthreads/images/graemlins/beerchug.gif[/img]

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It wasnt the pipe diamtere that was too large (was in fact still a bit small) but its the overall dimensions. With it on the turbo, it was too wide and hit the gearbox cables and i couldnt get the turbo back on the manifold. The best bet is the samco TIP... Straight swap and will give you a better intake..smoother and generally better made.

Rich

Rich

Gotcha

[img]/ubbthreads/images/graemlins/beerchug.gif[/img]

after my Jabba remap my car still scares me a little when the power catches me off-guard

although i would like to get the funds together for a turbo upgrade to a K04

Rich, yours should be more than enough fun when its done chap! [img]/ubbthreads/images/graemlins/laugh.gif[/img]

[ QUOTE ]
Dean_T said:
after my Jabba remap my car still scares me a little when the power catches me off-guard

although i would like to get the funds together for a turbo upgrade to a K04

Rich, yours should be more than enough fun when its done chap! [img]/ubbthreads/images/graemlins/laugh.gif[/img]

[/ QUOTE ]

Hi Dean,

Have you posted before/after plots of your Jabba remap?

no not yet, cant get my hands on a scanner as yet

i guess i'll have to get some batteries for my digi-cam and get it done that way

So what TIP do Jabba usually use for the IHI inlet??

Jabba are building their own silicon intake hose, but it's was going to be ready in 2 weeks, 3 months ago. Current estimated delivery is 2 weeks.

Jabba have only fitted 4 kits, and they've fabricated an ally intake and then cut the standard hose and slipped it over the ally piece.

This is too complicated for a production kit, so they're sorting a silicon one (eventualy)

Ah, I see.

So does anyone know what the subaru intake looks like as these turbos are fitted to them.

A cut and shut from one of those possible??

John beat me to it!

As he says they fabricate the bottom out of alloy pipe and slip over the top end of the OE one.

My current plan is to fabricate the botom out of 2.5" stainless i have (cut at 45 degrees and re-welded to make 90 degrees), attach it with silicone hose and then modify the SAMCO TIP i bought to fit over the stainless. Took me ages (with some help from john..Cheers mate!!!) to figure it out as nowhere could give me a definate answer what needed doing. Going to speak to AmD about the map when i take it up about the map. Looking for about 1.3 bar sustained boost and an increased redline to about 7500rpm. Going to start saving for the engine rebuild with S3 rods and JE low comp pistons so i can wind up the power a bit more.
Rich

[ QUOTE ]
HTC said:
Ah, I see.

So does anyone know what the subaru intake looks like as these turbos are fitted to them.

A cut and shut from one of those possible??

[/ QUOTE ]

Looking at the forge website, it looks a bit large to fit in the space still [img]/ubbthreads/images/graemlins/frown.gif[/img] also its £200! [img]/ubbthreads/images/graemlins/crazy.gif[/img]

Okay, just a thought. We want to see this car finished as much as you do!! :-)

[ QUOTE ]
HTC said:
Okay, just a thought. We want to see this car finished as much as you do!! :-)

[/ QUOTE ]

[img]/ubbthreads/images/graemlins/grin.gif[/img] Im getting a bit excitd as it nears completion, and from what Johns said about his, i cant wait for the results!

Rich

Ive atleast completed the FMIC install... plumbed in from turbo outlet to throttle body and the bumper is back on so i am getting somewhere at least! Looks pretty damn mean! Going to get the pipework powder coated black and the intercooler core anodised black to make it a little less obvious!

Also got a definate figure for my insurance too from adrian flux.. £1300! [img]/ubbthreads/images/graemlins/groovy.gif[/img] Not at all bad! considering i paid £1100 last year for STANDARD car! Thats EVERYTHING fully declared with a 5000 mile limit on mileage! Will be trailering it to car shows from next year onwards to keep the milege down...also means i can run it on the drag strips completly empty and get some good times..

John, we have to have a run against each other at GTi next year! Would be a very close one i think! [img]/ubbthreads/images/graemlins/grin.gif[/img]

Greg the conversion requires completely new software, as it's running a larger maf, larger injectors, and a much larger turbo.

Yep.. I doubt it would even run on the existing software.. fuelling especially would be WAY off! AmD are mapping it for me next week and they are also fabricating the downpipe. This is bing liked to a Milltek hi-flow sports cat and then onto my eisting Milltek exhaust system.

Rich

Cheers.

I have a K04 conversion on my A4TQS and am starting to wonder if I made the right decision. At the time there wasn't much information on other options - I am expecting about 240-250 BHP when everything is finally sorted - the install got seriously complicated when engine problems were discovered; now have a new bottom end which I am having to run in [img]/ubbthreads/images/graemlins/mad.gif[/img]

If anyone has any suggestions guess I could always sell the K04.....

The IHI kit is made for the transverse engine only unfortunately... the turbo orientation is completely different on the A4 to the A3/Golf .etc. Must be a way but would require serious moification to turbo and manifold.

Rich

I don't think it would rich. I've deen pics of a 28rs on an a4 and it looked the same configuration as the IHI to me.

Did 290hp 290lbft on jbs rollers today, at 1.3 bar peak, 1.15bar sustained boost. Standard cars were within 1% of manufacturers claims, so the rollers are bang on.

Well it goes up2 AmD today! Got a few hours to finish off the intake... What ive done is fabricate an intake pipe out of stainless steel and then i will modify the samco TIP to fit over this, then adapt the end to fit in the large MAF. got a fair bit of work to do before taking it up but should JUST get it done in time...it doesnt come any closer than this! Anyway,

ROLL ON THURSDAY EVENING!

Rich [img]/ubbthreads/images/graemlins/groovy.gif[/img]

Forgive my ignorance but what difference does the FMIC make? Does it allow you to run a higher boost pressure or does it just keep the charge air at a lower temperature?

What im getting at is if a put one on my S3 will it allow me to a bigger gain after a re-map?

[ QUOTE ]
nervus said:
Forgive my ignorance but what difference does the FMIC make? Does it allow you to run a higher boost pressure or does it just keep the charge air at a lower temperature?

What im getting at is if a put one on my S3 will it allow me to a bigger gain after a re-map?

[/ QUOTE ]

Well you can turn the boost up BECASUE of the FMIC allows you to cool the air more effectively...or it just cools down what boost you already have...either way, a good thing to have.

Rich

You won't get much more than that amount safely as you will be running at the limits of the K04 charger.

vw/audi turbos are really small. You'd need to think about doing what rich is to get big power.

[ QUOTE ]
nervus said:
So With a FMIC and a jabba re-map could expect much more than 270 BHP and what sort of boost pressure increase could i run safely?

[/ QUOTE ]

You won't get much more than 270. There are safety features on the car that stop you overboosting. With the FMIC you will have more "stable" power, where as the power can be quite random at times with standard IC's. At 270bhp+ the standard injectors will be running more or less flat out. So u would need a bigger turbo and injectors to get much more power.

I think you might get a little more torque from the FMIC, should take you 300+ with the right boost set up.

Is the turbo your using an IHI VF34 Roller bearing turbo?

If so, what else apart from the manifold do i need to fit this unit to my S3 in Jabba's kit and will they supply the manifold etc separately?

[ QUOTE ]
nervus said:
Is the turbo your using an IHI VF34 Roller bearing turbo?

If so, what else apart from the manifold do i need to fit this unit to my S3 in Jabba's kit and will they supply the manifold etc separately?

[/ QUOTE ]

Yes it is the VF34!

You need the turbo, manifold, oil lines (you will need to get an oil feed line made somewhere as the OE one just wont fit!) cast exhaust housing for turbo, a downpipe will need to be fabricated on the car... very costly at pretty much a full days labour!, and you will also need to link up the original intercooler plumbing. As for the intake, dont waste time trying to get the original one to fit! there is JUST no point! Buy a samco intake, chop the bottom off and make a intake pipe out of 2.5" stainless or aluminium.

All in you would be looking at close to £5000 with the car back on the road.

if i were doing this upgrade again, i could easily do it in 2 days with all the right parts... The hard bit is figuring it all out in the first place. Also, i could do it cheaper as i could get the right parts first time. Would not want to have to do it on an S3 tho! the transfer box at the back would seriously get in the way and make any movement near impossible.. not pleasent!

Rich

Buy the manifold. Get a turbo off the net from the US, fab up a u bend to come off the turbo, to avoid the transfer box, and then mate it to your stanard downpipe.
Get a hydraulics place to make up som flexible oil and water lines to complete. Buy some 440cc or bigger injectors, and get it mapped.

To be hones a lot of cash to get an extra 40-50hp over a chipped s3. Well worth it on an a3T though for the extra 100hp.

[ QUOTE ]
GolfTTish said:
Buy the manifold. Get a turbo off the net from the US, fab up a u bend to come off the turbo, to avoid the transfer box, and then mate it to your stanard downpipe.
Get a hydraulics place to make up som flexible oil and water lines to complete. Buy some 440cc or bigger injectors, and get it mapped.

To be hones a lot of cash to get an extra 40-50hp over a chipped s3. Well worth it on an a3T though for the extra 100hp.

[/ QUOTE ]

Oh i dont know... the difference may not be as much over a chipped S3, but ignoring peak values, the power will be spread alot more over the revs and WILL be a much quicker car... just not as much as the Golf/A3. The golf's and a3's will, however, still p1ss all over the S3 due to the huge weight difference... were talking near 300kg! Thats 1/3 of a ton!

Rich