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My Yellow FR ARL TDI Now with WMI Fitted

MattFrench

No poke without smoke
Jan 16, 2007
112
0
www.rsfrench.com
Purchased my car November 2006, with 6,000 miles on the clock showroom condition from Frosts seat, down in Worthing. One Month Latter the modding commenced. I am looking to create an OEM + look with that bit more Power.

1st Mod

Becker head unit to match the OEM look.
Purchased this from Pixmania for £250.
A great upgrade with the built in handsfree kit, well worth every penny.
With a few spare Penny’s I fitted a Green panel replacement filter.
My Opinion was only worth doing if you need a new filter, The main advantage is that is clean able.


Remap

Next was a trip to Jappasprt for a Full custom remap £425 all in.
Initial rolling road made 157bhp
After the remap made 197bhp and 314 ft/lb Torque :D , :D
As you can imagine the drive home was very pleasing.
Thank you all a Jabba for an Excellent service.

Set of new tyre needed, 4x Michilen pilot sports fitted, What a tyre, In a different league to the bridgestones.


New Clutch ARB'S Polly Bushes and Dogbone Mount


3 Months latter and not such a happy face, My clutch had started to slip, so it was booked back into Jabba for a full sacsh kit, for around £750 fitted, As well as the clutch because of the distance I have to travel from Kent I had a set of front and rear ebaich anti roll bars, poly bush kit and an up rated dog bone mount.

My impressions of the above modifications.

Clutch: You could defiantly feel the difference over OEM, and after a while I have become so custom to it I like it!!

Arbs: Best handling improvement I have ever done. Really makes the car handel well.
Polly bushes: A cheap mod and stiffens up the front nicely.
Dogbone mount: Stopped wheel hop, an easy upgrade and worth the money.


Brakes:


Now that I had the power and the handling I needed to be able to stop.
I initially upgraded my front 288mm discs to 312mm. There was a noticeable improvement but not enough. After a few months I decided to upgrade my brakes again, I purchased a set of Brembo calipers with 323mm Discs in black, As these fitted behind the FR+ Wheels just.

I then upgraded the rear, LCR calipers with anniversary carriers again painted black, As I don’t want my car looking like an LCR, it’s a diesel and I want people to know it’s a diesel.

Oh and another set of tyres just the fronts this time.

With the brembos bedded in nicely. They are a great improvement over the 312 single pots.


Bmc cda and SFS silicon pipe upgrade.


Brought the CDA of a fellow member, A worth while upgrade made the car rev more freely.

With the SFS system, this was brought due to a boost leak on the intercooler pipe connector (pipe 4) It solved the problem with the leak, and definitely looks the part.

However initially you could feel the pipes expanding on, and now there are roomers of a reinforced version coming out. Basically I have mixed feelings. Its stopped the leaks but I think the kit needs to be reinforced. Its easy to fit but there are a lot of wear point that you have give a lot of attention to.

Have been running this setup for a 6 months or so, when I made the decision that I was going to keep the car for a total of 5 years rather than the possibility of 3 when my finace had finished,

So I booked it in for a Full Miltek non Resonated system from AMD,
What a **** up!! .Took nearly a whole day to fit.
But I have a 2.5’’ ARL150 down pipe and a 2.75’’ LCR resonated system, Not what I wanted, but they agreed to change it for a no resonated system.
The fitting took so long due to my car being a FR+ so the down pipe had to be altered. Full praise to AMD though for there efforts, most would of told me they dont sell an exhaust for my car.


So that was then this is Now !!!! All work going to be carried out by myself!!

I have decided to go down the hybrid root. I am changing the turbo as we speak.

First purchase,

New bike to get to work on lol
CIMG0860.jpg


I have decided to go down the TD route, They quoted me 595+ Vat to hybrid my own turbo.

Set taking out the turbo early one Saturday morning. 2hrs latter the turbo was out.
I took the turbo out from the top, by taking the inlet manifold off first.

CIMG0831.jpg


Things noted on removal, Both manifolds were leaking on a single port. And a boost leak from the other side of the intercooler.

Some pictures of the turbo out of the car,

CIMG0834.jpg


CIMG0835.jpg


CIMG0837.jpg


In future from what I know I am going to have o spend with SFS with silicon and clamps I would of got a Eurojet intercooler or forge upgrade.

Turbo was sent off Monday Morning.

Have since ordered A devils own WMI Kit, from badger 5 £289 + Delivery
A race pipe from formally allards of of ebay.
Car is booked in for a remap on the 17th June at RS Tuning Leeds.

In the mean time am removing my EGR cooler and cleaning my inlet manifold and waiting for the turbo to return.

CIMG0832.jpg


Picture of egr cooler.

To remove this 2x coolant hoses have to be joined together and a t connector replaced with a straight join. Then you can remove and put an EGR blanking plate directly on the manifold so you can then add a thermocouple.

I will be posting up more photos, when I next get the car out of the container, and the turbo and WMI kit arrives. I’m hoping its here by Tuesday which will give me time to order up all the fitting studs gaskets etc.
 
Last edited:

MattFrench

No poke without smoke
Jan 16, 2007
112
0
www.rsfrench.com
Right all the bits arrived, So an resonalble start for a sunday, Got the car out the container.
CIMG0861Large.jpg


CIMG0862Large.jpg


CIMG0864Large.jpg


Must check its a stage 2 unlike other tunners!!

CIMG0867Large.jpg


CIMG0868Large.jpg


CIMG0869Large.jpg
 

MattFrench

No poke without smoke
Jan 16, 2007
112
0
www.rsfrench.com
In order of events,



Fitted the racepipe to the cleaned manifold.

Blocked off the EGR outlet directly on the turbo.

CIMG0874Large.jpg



Using the standard pipes and a 22mm speed fit plastic pipe remove the egr cooler and connect the two hoses together.

CIMG0873Large.jpg

No T going to the Coller

CIMG0871Large.jpg


Joined coolant hose and no EGR Cooler


The Junk
CIMG0870Large.jpg



With all that junk out the way fit the turbo.

CIMG0876Large.jpg


Install the oil feed and return. and prime turbo with oil.

Istall the manifold.

fit the boost hoses to the turbo.


CIMG0880Large.jpg


CIMG0881Large.jpg

With everything back together and the addition of a braket to hold the vacume resivoir.

I then filled it with oil and topped up the coolant. With this turbo I have decided to change the oil evey 3000, so brought 20 litres from TPS for £65 and 4 filters. I m prepared now.

Took it for a test drive and all seems to be ok. Think I have a boost leak which was expected, but need to gee sfs up or come up with something myself.

Remap 17th June R.S.TUNNING, But before then I had to fit my WMI. Roll on next weekend!!!!
 

UncleFester

Grumpier by the day!
Apr 30, 2006
4,764
1
Milton Keynes
www.facebook.com
Nice job Matt - didn't realise you were quite so handy with a spanner! I see your pipes rub in the same places mine do :)I have a trial of some different boost pipes next week - well a final fit test anyway, will let you know how it goes as this will replace the restrictive pancake too :)
 

MattFrench

No poke without smoke
Jan 16, 2007
112
0
www.rsfrench.com
nice project mate.
may i ask where you got the carriers to adapt the brembo calipers.
what was involved??

The brembo calipers that I got were off fleabay, thy were the GT kit. They just bolt on. However the LCR's Brembos are a straight fit too. All you would need would be the brake lines of a LCR.
 

MattFrench

No poke without smoke
Jan 16, 2007
112
0
www.rsfrench.com
Nice job Matt - didn't realise you were quite so handy with a spanner! I see your pipes rub in the same places mine do :)I have a trial of some different boost pipes next week - well a final fit test anyway, will let you know how it goes as this will replace the restrictive pancake too :)

Boost pipes are my only worry. With the race pipe being shorter than the egr and the connector ataptor the SFS pipe at the gooseneck 90 has not got much contact and had pulled everything to the Right which im not happy with.

Ill look out for your results as Im leaking at pipe 4, and its got to be fixed before it goes for a remap.
 

MattFrench

No poke without smoke
Jan 16, 2007
112
0
www.rsfrench.com
Re my front brembo brakes no, I did not use the same carriers, 4 pots do not use a carrier system as each pad are aplied by there own piston well 2 in fact with 4 pots.

Before I had these Brembos I went from 288mm to 312 mm front discs where you can use the same carriers and pads.

With reference to the rear to upgrade the size of the disc to the 256 vent i now have you have to change everthing. and nothing can be retained except hoses.

Hope that all makes sence.
 

MattFrench

No poke without smoke
Jan 16, 2007
112
0
www.rsfrench.com
An Update,

Watermethanol still not fitted as waiting for some nozzels from badger.

However the car went to R.S.Tunning today,

was running just shy of 200bhp on the standard map, with the rs custom map and several hours of tweaking the power ended up at 230 bhp and 370lbft torque.

I give alot or credit to paul and the map is so smooth and pulls right round from 2000-5000 rpm, its a weapon.

And with the resonated exsaust its pretty stealth too.

Il post up a graph when i have access to a scanner and you will see what i mean.

Oh and purchased a tunning box for further tweaks of wmi, etc.

On the juourney back I went cross country from leeds to lancaster where you could skip by traffic if they were stationary. Very little smoke.

Map was set to peak at 1.9bar and hold at 1.8 bar.
Paul said theres still more fueling to give so should see more with wmi if i ever get round to fitting it.
 

jonjay

50 Years of 911
Jun 27, 2005
5,843
1
Essex
Cars is fab Matt. How you getting on with the SFS hoses? If you remember from our conversation at AmD mine were expanding with the big turbo....?
 

MattFrench

No poke without smoke
Jan 16, 2007
112
0
www.rsfrench.com
sfs hose, product 50% satisfied, yes there is some expansion, and its noticble, and would effect performance ever so slightly as you can feel the surge of air expanding the pipes and then going on full boost. I will take some logs of this soon. But its ok.

Service 100% cant fault them sent me pipe 4 over night so i could fit it in time for the remap.

Interested in the alloy kit your having done. But am looking at how much is it worth spending on the car, clearly now for me the easy modds with the biggest gains are done unless i chuck what i already have eg clutch, turbo, hoses,


Do love it though.
 

jonjay

50 Years of 911
Jun 27, 2005
5,843
1
Essex
Well watermeth is a step in the right direction. My only concern is how the SFS hoses will last given the amount of boost you will be running once the meth is been mapped into the ecu.
 

MattFrench

No poke without smoke
Jan 16, 2007
112
0
www.rsfrench.com
Water Methanol Fitted

Nozzels eventually arrived from bill Friday,

So yesterday I was fathing around fitting the kit, took around 3 hours, Hit a brick wall fitting the nozzel adaptor to the silicone as it got in the way of the spray so this moring at 10am i was outside screwfix getting the right tap.

I moddified a hose connector and tapped the 1/8 NPT thread into it.

Alll back to getther and working, Will be going out for a run later on today to see if there is a difference. Mainly looking at elimiating smoke.

Well heres some pics for you.

Nozzel Mounting
CIMG0894Medium.jpg


Controler and float indicator mounting
CIMG0895Medium.jpg


Tank and pump in boot
CIMG0897Medium.jpg


The tank and pump was mounted on a piece of ply and then velcoed to the carpet so it can eassily be romoved if Needed.
 

jonjay

50 Years of 911
Jun 27, 2005
5,843
1
Essex
So neat and tidy mate. Looks superb :) and I am jealous. Glad to see your pushing the deisel tuning!
 

jonjay

50 Years of 911
Jun 27, 2005
5,843
1
Essex
Matt,

where you been of late? How you getting on with the WMI. I am getting the same kit but not sure which nozzle size to go? Any ideas matey?

Cheers
Maz
 
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