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Facelift Unitronic Inlet elbow

T-1000 May 20, 2020 at 10:55 PM

  1. T-1000

    T-1000 Well-Known Member Team Glacier Sportback Audi RS3 5 Cylinder

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    Finally got around to fitting the Unitronic turbo inlet elbow.
    Thanks to Simon Sharp @TTE For the Elbow.

    Fairly straight forward install......

    Unitronic official instructions say it can all be done from the top, unlike I.E and Forge which require the lower cast pipe to be removed to access the inner elbow bolt.

    I opted to do it all from the top.


    First up remove the engine cover to expose the coil packs etc.
    Then remove your intake pipe
    [​IMG]
    Undo the coil pack connections to number 1 & 2
    [​IMG]
    Then unclip the cam solenoids on 1 & 2 by pulling back on the red lock tabs then pressing down the black tab.
    [​IMG]

    Undo the cam sensor

    [​IMG]

    Undo the 3 nuts and move the coil wiring bar out of the way.
    [​IMG]
    Then remove coil packs 1&2
    [​IMG]
    Next turn your attention to the boost vacuum line.
    Undo the support bracket on the side of the oem elbow, a Torx 30 bolt
    [​IMG]
    Pull the vacuum line off the actuator and at the point near number 2 coil pack where it connects to the silicone line.
    [​IMG]

    Next undo the Actuator off it’s mounting point and pivot arm, 2 x 10 mm nuts and a circlip on the wastegate arm
    [​IMG]
    [​IMG]
    Then let the actuator go through the mounting hole so it’s out of your way
    [​IMG]


    Next you’ll need to undo the 2 off Torx bolts that hold the oem elbow in place.
    The inside one is a tricky one to remove but with patience it can be done, you’ve just got to get a ‘feel’ for where it exactly is and how to get the ratchet/Torx bit onto it, I found 2 hands for locating the bit easier, once you are in the bolt head it’s just a matter of loosening it enough to remove it by hand, carefully so you don’t drop it.
    Once you have removed it then you can undo the easier outer one that you can actually see.

    I’ve arrowed the one you can’t see, it’s directly opposite the circled top one.
    [​IMG]

    Once you’ve undone those 2 Torx bolts then you need to undo the breather pipe from the engine PCV system.
    3 Torx screws to be removed here
    [​IMG]

    Now you can withdraw the old elbow
    [​IMG]
    Next you’ll need to remove the breather pipe from the old elbow.
    It’s locked into place with a security fastener
    [​IMG]
    Use a Dremel with a grinding disc to cut a groove into the head and remove with a flat blade screwdriver.

    Once the bolt is removed pull out the breather pipe and insert into the unitronic pipe, using the Allen bolt supplied to secure.
    [​IMG]

    Transfer the flange seal ring from the old pipe to the Unitronic pipe.
    [​IMG]

    A shot here of the area you are putting the new elbow into.
    [​IMG]
    The above gives you an idea of exactly where that inner Torx bolt needs to go.

    Take the Unitronic elbow and insert carefully into the turbo opening, keeping an eye on the seal (don’t let it fall off).
    Once it’s in place you can insert a Torx bolt to hold it in place, just do it up by hand for now, next insert the rear Torx bolt, I started mine by hand carefully and screwed it in as far as I could by hand before finishing with the ratchet.
    Then tighten the one you can see, ensuring the flanges are seating together squarely.
    [​IMG]
    Refit the actuator and reconnect the wastegate rod with the clip.

    Refit the actuator vacuum line, I connected it to the actuator 1st and to the connection near the coil 2nd ensuring it was seated correctly around the new elbow then tightened up the bracket bolt.

    Reconnect the breather pipe to the PCV system making sure the pipe sits in its place at the back under coils 1&2
    [​IMG]
    Once done it’s just a matter of inserting the coil packs you removed earlier, bolting them down, refitting the coil wiring bar bolting that down, then reconnect the coils/Cam solenoids/cam sensor.
    You’ll then have your new elbow ready to put your hard pipe back into.
    [​IMG]
    Hard pipe fitted.
    [​IMG]


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  3. Sequence

    Sequence New Member

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    Great walk through! what a f****** pig of a job:blink:
     
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  4. domino_z

    domino_z Member

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    So you used a 3.5” to 3” coupler to make it work with forge hardpipe?

    Or Is that coupler that comes with the hardpipe?
     
    Last edited: May 21, 2020 at 6:32 AM
  5. T-1000

    T-1000 Well-Known Member Team Glacier Sportback Audi RS3 5 Cylinder

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    It’s the coupler that I was already using with the Forge Hard pipe so yes 3-3.5”.


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  6. T-1000

    T-1000 Well-Known Member Team Glacier Sportback Audi RS3 5 Cylinder

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    The worst part is removing that inner torx bolt, however once you get the knack its not that bad, like most of these jobs once you've done it you are familiar with it.

    I suppose another option would have been to go underneath and remove the lower cast pipe, which some people may find the easier route, however i wasn't going to let one bolt stop me :thumbs up:
     
  7. T-1000

    T-1000 Well-Known Member Team Glacier Sportback Audi RS3 5 Cylinder

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    For anyone who wants to go from underneath.

    Some pictures from another install guide.

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]


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  8. T-1000

    T-1000 Well-Known Member Team Glacier Sportback Audi RS3 5 Cylinder

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    I’ve found out yesterday there’s an issue.
    RHD cars can suffer from the inlet touching the tip of the brake servo.
    Under hard acceleration 3.5-4K you can feel the engine through the pedal.

    There is only 8mm clearance even with the black shield removed.

    It’s not enough because the engine movement must be more under Sudden loads.

    DO NOT BUY THIS UNITRONIC INLET.
    I HAVE REMOVED MINE AFTER DISCUSSIONS WITH THE SELLER.


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  9. domino_z

    domino_z Member

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    Thanks for the heads up

    Best to stick with forge, designed on a rhd car

    Tbh even without the fitment issue, I’d choose the forge inlet for their hardpipe just to avoid the step down
     
    Last edited: May 22, 2020 at 10:04 AM
    T-1000 likes this.
  10. Sequence

    Sequence New Member

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    Thats not good.. what as Simon's response ?
     
  11. T-1000

    T-1000 Well-Known Member Team Glacier Sportback Audi RS3 5 Cylinder

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    Very helpful.

    Advise given about a potential further issue If it was left on and full refund issued.

    Forge ordered, however I must say the supplier of the forge (Awesome) wasn’t very accommodating in that they are local to me and wouldn’t let me pay over the phone then go down to collect it (told them to leave it outside the door)
    They also wouldn’t even entertain a Saturday delivery when I offered to pay !


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  13. T-1000

    T-1000 Well-Known Member Team Glacier Sportback Audi RS3 5 Cylinder

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    Further update.

    I was advised to Re-clock the Uni inlet by undoing the Torx screws and rotating it backwards to the engine.

    It did move a little bit but not enough in my eyes.

    Since doing this I had a phone call from Simon saying that Unitronic had shipped the wrong elbows and of the 5 he had in stock 1 was the revised part.

    Simon has arranged for this to be at my house tomorrow before 12.

    This is what I’d call great customer service.

    I’ll update again with pictures for the revision fitting etc.

    Below is how close it is now.
    [​IMG]



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  14. Sequence

    Sequence New Member

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    I have head good things about Simon so its great to see it is actually true. Pain in the backside we have one of the most necessary things in the ****** way!
     
  15. Ross_T_Boss

    Ross_T_Boss Member

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    That sucks, I'm a bit surprised the wrong ones got sent - here's one I got, the revised part should basically have a machined indent that gives additional clearance to the brake reservoir during engine movement.

    IMG_5802.jpg

    Seeing how much the engine can move at Stage 2 it's not a total surprise, I've wondered about BFI stage 1 mounts to keep things a bit tighter, just concerned they are a bit more NVH than I'd be happy with.

    Mine is not fitted yet, Forge unfortunately butchered my stock PCV hose when then removed and I only found out whilst swapping it over to the UNI inlet.

    I'm glad you to got it sorted - would have offered to send mine across otherwise!
     
    T-1000 likes this.
  16. T-1000

    T-1000 Well-Known Member Team Glacier Sportback Audi RS3 5 Cylinder

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    Same here, he’s been superb over this whole matter.
    Simon is an example to other businesses on how to sort a problem out.


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  17. T-1000

    T-1000 Well-Known Member Team Glacier Sportback Audi RS3 5 Cylinder

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    Update.

    Replacement Elbow came today.

    Spot the difference.
    IMG_9349.jpg

    You can see here the elongated holes that allow you to fine tune the fitting.
    IMG_9350.jpg
    Much better clearance now
    IMG_9351.jpg

    Here’s a tip.
    Fit the elbow but don’t tighten the Torx bolts fully, fit your coupler and adjust to suit, this is a picture with my coupler fitted before I had to move it forwards, you can see the slight ‘flat’ in the circumference, this is where the coupler is touching the Cam solenoid connector, move the elbow slightly forward then tighten up the bolt you can see on the elbow.
    You can then remove the coupler and tighten up the hard to get to Torx bolt.
    View attachment 203412

    After road testing I can say everything is now fine, there is no servo and elbow contact under hard acceleration.


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    Last edited: May 23, 2020 at 8:11 PM
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  18. D0C

    D0C Well-Known Member Team Panther Team Nardo Audi RS3 TTRS

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    As someone who knows nothing about these things, does the fact there is now an indent mean less or not as good air flow?
     
  19. T-1000

    T-1000 Well-Known Member Team Glacier Sportback Audi RS3 5 Cylinder

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    No it’s just machined out of the casting.

    Inside is same as the other inlet.
    So still smooth.
    IMG_9323.jpg


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  20. D0C

    D0C Well-Known Member Team Panther Team Nardo Audi RS3 TTRS

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    Next question...why don’t they machine more of it out? Less weight etc or would the structural integrity be compromised?

    Anyway, looks good and glad it’s sorted!
     
  21. T-1000

    T-1000 Well-Known Member Team Glacier Sportback Audi RS3 5 Cylinder

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    Don’t forget this was designed to fit LHD cars where the servo is on the opposite side.
    The scallop cut is just for RHD cars.

    I’d imagine there’s no reason to make it lighter really as it weighs very little anyway.


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  22. T-1000

    T-1000 Well-Known Member Team Glacier Sportback Audi RS3 5 Cylinder

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    The coupler image didn’t upload for some reason.
    IMG_9352.jpg


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  23. T-1000

    T-1000 Well-Known Member Team Glacier Sportback Audi RS3 5 Cylinder

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    A video showing the range of adjustment you have once it’s on.

    As I’ve said above leave it loose then put your coupler on, then you can make sure you aren’t resting on the cam solenoid connector.
    Once happy you can tighten up the bolts.




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