How To Fit a K03 TIP

OK, so here we go...

Well I was quite happily reading Michael Jackson jokes on the internet when I was disturbed by a knock on the door...."FANTASTIC" I think, Kelly Brooks come over but no, its a UPS man delivering my brand new shiney Forge TIP. Due to the chance of Kelly Brook coming to my house was slim at best I decided I'd better have a look at this TIP......its quite an elaborate bong I must say...



Nice and smooth inside..





All good. So I pop out and pick up a load of jubilee clips as I dont want to get half way through and be stuck...

I wasnt going to take any chances so picked a load up...



So its out into the garage to start things off..

Firstly, engine cover off to reveal what I was going to be bashing my fingers and arms off..



Then its airbox off time, first the top half....making sure you unplug everything from the ignition module (I think) and the MAF....



The the bottom half of the airbox has to come out....2 x nuts to undo...one at the front and one at the back, then lift the airbox out and put it somewhere safe (Make sure you put all the bolts, screws and plug clips somewhere safe as well)

Now you'll have something like this...



I decided to take remove everything from this end of the TIP at this point, DV etc etc. Its just a case of un-doing everything and giving them a pull out...



So thats the top half sorted out...

Now its time to get the car jacked up (axle stands please people...dont like hearing about people being squashed by cars falling of jacks!!).

In this pic you can see the bottom cast section of the TIP. There's small 5mm allen bolt that is holding it onto the turbo. Mine was easy enough to get un-done but thigs are a bit tight down there...



This little bolt is the only way the TIP is held on at the bottom end. Once it was undone I used a small pry bar to careully split the TIP from the turbo....



Once this was clear from the turbo I removed the small pipe that goes onto the TIP at the bottom...some pliers, a deep breath and a "F*CK OFF" finally got it shifted.



It wasnt tight, just really hard to get at with pliers....I shouldnt have lent my mate my long reach needle nose's...oh well.

Right, now you can pull the TIP out of the engine bay from above, carefull as you do it as mine managed to catch on pretty much everything on the way up.

Here she is....off at last...



Time for a pint of ice cold ribena at this point and 5 minutes sitting in the sun....

Back to work...

You can see here how the Forge TIP varies over standard...

Standard item looks quite restricted....bit of a bottle neck there I'd say...



Forge item, a nice proper bend with an even radius....looking good, hopefully should make it a bit easier for the air getting in.....




So this is where you have to thread the TIP onto....aw...bless....look how small it is...



Anway, clear any crap/gunk off the turbo prior to fitting the new TIP.

This is where the fun started. You have to thread the TIP down through the engine bay and get it down towards the turbo. This was VERY TIGHT, in fact so tight, I had to cut a small amount off the turbo end of the TIP (about 8mm) otherwise there was no way it was going on. Make sure you put the jubilee clip on BEFORE YOU THREAD THE PIPE, YOU'LL NEVER GET IT ON WHEN ITS IN THERE!! (you have been warned).

So anyway, after a bit of jiggery pokery the pipes sitting roughly where I need it so its under the car again..

After a lot of pulling and poking and swearing I finally got the TIP onto the turbo. I had to use a pry bar to move the TIP around into place as I couldnt get my hand in there...



Now its a case of pushing the jubilee clip up as close to the turbo as you can and doing it up....



Re-attacht the other little hose at the bottom onto the little alloy pipe and thats the bottom half done.

Back up top you'll now be left with something like this...



Now its just a case of refitting everything back into the TIP, nice and easy...



Refit the airbox....bottom in first...



Now at this point I tried to refit the top half of the airbox and MAF etc but the new TIP was too long to get it all to sit right. So...out comes a very sharp stanley knife blade and I trim a bit of excess off. I attached a jubilee clip that I could use as a straight edge to ensure a nice smooth cut.

It only needed a bit taking off...



So now I can refit the top of the airbox and MAF and plug everything back in, engine cover back on etc.

Now we're there....fitted.....phew!...






So thats it....done. Took about an hour and a bit to do. its tricky and ****** tight on mine, mines a 1.8T AGU running a KO3 turbo just for reference.

So now its a case of starting it up and making sure its OK, which it was. Tools away and back into the house for a well deserved cup of tea and a few slices of fruit cake to celebrate my victory...



Job done, nyom nyom nyom :thumbsup:

Yeah its easy enough to do...... its just REALLY tight down there, if I had access to a proper 4 poster ramp it would have been a lot easier. It was all done with me on my back under the car trying to squeeze my arms round driveshafts and antiroll bars. Its just fiddly, small hands and weather thats not 30 degrees would have been a great help

I've not driven the car yet, I'm off out for dinner in a bit which will involve a drive down some nice twisty country roads so I'll have a play and see whats what.

Tom

T

I should also add at this point....big props DPM Performance.

I ordered this the day before yesterday during the evening. It turned up at lunch time today. Very speedy service and a great price

T

jesters3 said:

Nice write up, well done for taking the time and photos!:thumbsup:

Click to expand...

no worries.

I couldnt find a decent guide online so thought I'd do one myself to save anyone else the head scratching

Well its not fallen off yet so thats a good thing.

I doubt it gives any extra ponies but the car does seem to pick up better, mainly at higher revs rahter than low down, could be due to the new TIP not having that massive restriction on it perhaps?, anyway...all good.

The DV also sounds different now, more of a 'psshhhhht' than what it was before.

Cheers

Tom

Beenon for a few days now and its still not fallen off

Car feels fine, as I said it seems to pick up a bit better.

I will be changing the rest of the hoses at the end of the month when payday rolls around

Cheers

Tom