Daniel's Seat Ibiza Sport PD130. Project HYBRID!

[dann2707]

Hey.

I was looking for a Seat Ibiza Sport with the PD130 engine as i've heard amazing things about the torque, economy and how much power you can get out of it after a few mods. So I finally found one...

It was advertised at £1600 and was in Kent (I'm from Leeds). So I booked the train tickets to go see it, bit of a gamble really as I kinda had to buy it!

I got there and was instantly let down The wing mirror was held on with tape and it had quite a few dents around the car despite the guy telling me it was in really good condition.

The worst part of it was the horrible horribbbleeee sound that started after a few mins when the engine was on... suspected dying DMF. I was even more annoyed. But with a bit of bartering I got him down to £1200.

Cash exchanged I drove it home at 8pm from Kent. I got home at around midnight, went straight to bed as I'd been travelling on trains for 6 hours haha! The car seemed to go well considering its been neglected a bit.



Anyway, I know with diesels they get super clogged up due to the EGR. My aim for this car is to get it running absolutely spot on before I remap it. So I started with cleaning out the EGR and inlet manifold which took forever. It's done 120k miles so it was safe to say it was pretty clogged up!

I'm a bit of a MPG hunter and always strive to get the best when I'm on long runs but I also absolutely love back roads, a nice combo of both is good I think

This is the car!

Pics of me cleaning the EGR and inlet.


Before:

After:

I then ordered a single mass flywheel and clutch kit from eBay for a price of £260. I've heard loads of things about the chatter being stupidly loud on the 6 speeds at idle but there is absolutely none. Really happy with the kit, all the shakes and awful sounds have now gone!

I then performed a LiquiMoly diesel purge, supposed to be much better than Forté as its concentrated not diluted in the tank.

I do however think I am losing boost, lots of oil on my connectors and I can hear a wooshing noise when going for it. I think its the intercooler too so I might upgrade to a FMIC asap.

Finally I created my own boost leak tester, but the system isn't even holding 10 psi so I think I do have a big leak somewhere! Can't seem to find it though as I have to hold my hand over a pipe to keep the pressure in so can't look around the car haha

And finally, after servicing the car fully and doing all the cleaning of the inlet etc I managed to average this across 26 miles from Uni the other day. Was really happy, but I did have to work for it

Tomorrow I'm getting a mufflerectomy and decat to release some horses and let the turbo spool faster!





Mods to come are:

FMIC
Remap
Sort the paintwork out
Hybrid turbo but not for aggggeees!


Thanks for reading

 

[m0rk]

Nice project. You're leaking round those Intercooler joints!

 

[dann2707]

I've secured them fully with heat shrink and they're absolutely solid now (apart from the one closest to the turbo) , didn't take any pics though

Fortunately the shrink is white too so it's easier to find leaks!

 

[rae1001]

Yep id say those joints in there are letting you down. Thats really badly leaking

 

[cupra.al]

its good that your sorting all the problems sorry i cannot help much more in the other thread.
that boost hose connection you have next to your fuel filter is probably a better place to connect your boost leak tester than where you have been trying.

 

[m0rk]

Heatshrink won't seal either - it'll blow still

 

[dann2707]

I beat my personal best for MPG today! Managed 83mpg average on a steady run from Uni back home!

I've been doing a few sorting out issues, my boost pipe is still leaking despite shrink wrapping it, so I went with a tried and tested method of cable ties. Seems to be holding boost a bit better now, might all be in my head though haha.

Notice the oil leaking at the bottom of the pipe!

You can see why it's leaking, the lugs are worn and the pipe is all scratched. Seal looks dead too compared to the other one (Pictured)

This one is good

My passenger side doesn't lock when you press the lock button in the car, it simply pops back up so I took it apart to see the root of the problem. Apparently the microswitch wears at an angle on the cam which plays all kind of havoc, so I took it apart and switch it around to give it more contact area. Fitted it all back together and the door isn't locking at all now haha, no power so I must have not connected something. Not all swings and roundabouts haha

Can see how it is on an angle, where it has worn away.

 

[dann2707]

I've bought a hybrid turbo!

 

[dann2707]

As my boost pipes are not all that I've also ordered the Airtec FMIC intercooler kit with all pipes, can't wait. Cost me £470 though!

My cable tie cheap mod is working well and no more oil is leaking for now yay.

I went to get the car tracked yesterday as the car feels dodgy to drive and my tyres are wearing away on the insides. Turned out the bushes in the wishbones were really badly gone, so much play.

So I drive to the other side of Leeds to pick up some new ones and bushes, really wish I'd gone for solid mount ones now but maybe another day, this has been so easy to do so far. Only problem I'm having is inserting the bush back into the console so im waiting for the garage guy to nip down to help me - be nice to people and they'll be nice back! haha

Drive to the other side of leeds was hellish, 2 hours in traffic and some dozy bast in a leon nearly rear ended me, ended up skidding and drifting right past me!!*

Old ones:

New ones:

The old bush:

No oil is leaking now

 

[cupra.al]

im interested to see the airtec cooler behind the prefacelift bumper i should think your have to cut a lot of bumper away.

 

[dann2707]

Uh oh don't say that! I'm handy with a grinder! haha

Gave the car a little once over with some stain remover as the seats are pretty awful. It worked to an extent but they could really do with being wet vacced properly!

The marks on the seats are where it is drying not the stains themselves. I really love the interior on these now, I just find it hard to look out of when at junctions. Might just because i'm a borderline midget though haha

Taken a few pics of the car too, not washed at all though. Used and abused haha

My passenger door isn't on properly, massive obvious line where it isn't lined up right. Easy fix?!

 

[dann2707]

So today I wanted to see where I could locate my boost gauge that I kept from my old car. I didn't want it on the A pillar as I find it restricted my view quite a bit before. The other choice was in one of the vents, the middle ones are a pain to get to and have to remove quite a bit of stuff and I wasn't prepared to do that so I chose the outer vent nearest to the drivers door.

Started disassembling the vent to see how I could go about it, bearing in mind this is the first thing i've done like this, was taking a bit of a gamble really as I know I could get a replacement vent for pennies if I mess this up.

So with my trusty snippers, files and measuring tape I cracked on!

Snipped this but completely off:

The gauge!

More snipping, not that tedious really

I measured the diameter of the boost gauge, then deducted that from the diameter of the vent where it will be sat, I then halfed the final figure to determine how much plastic to leave in the middle to make the boost gauge sit bang in the middle. White dots show where I measured it to:

Testing it in the vent.

The vents were loose ever so slightly loose as I had to remove the frame that held it sturdy, so out with the silicone I sealed around where it sits, currently drying.

Final product! Really happy with it to say it was a spontaneous decish today!

 

[dirtyD123]

have u fitted this yet? if so where did u run the pipe through the dash to the bay and where did u wire into for the ilumination on the gauge? cheers

 

[dann2707]

Wow I'm your first post I feel special haha!!

I haven't wired it up yet as I'm going to plumb it in when my ear delete pipe comes in a few weeks time. I'll update this when I have though. I'm going to get a feed from the light switch as it's only down the road from the heater vent.

There is a grommet somewhere that goes through the firewall but not sure where it is yet

 

[cupra.al]

there is one under the glove compartment kind of behind the airbox but a bit lower with the screen wash pipe going through it thats where i ran mine through on my old cupra.
might be a bit annoying running it to there though with your egr being on the opposite side of the bay and your gauge being on the same side as the egr too.

 

[dann2707]

Cheers for the heads up matey!

I got a knock at the door this morning and this thing was soon on my table!

The connectors look well made

 

[cupra.al]

that come well quick,i wonder if airtec sell the pipes on there own.

 

[dann2707]

I don't think they do mate!

I've fitted the boost gauge, it's not plumbed or wired in yet though as waiting for the EGR delete pipe first. I also cut the plastic couling behind it back a little and taped it off so it doesn't heat up the silicone sealant in the vent. Silver kind of stands out, I wish I had a black one now!
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Thoughts?

 

[dann2707]

Got another pic of the cooler, along with a intercooler selfie for a laugh, as seen it's bloody huge! (please excuse the double chin haha)

 

[-BH]

Nice u put so much photo's of it. That selfie made me laugh
I also want to upgrade my 1.8T with a SS FMIC. Only thing is I live in the Netherlands, can't order them here
Good luck fitting this!