Polo 1.8T! (KO4-023 & standalone ECU)

[str8ballin]

Hi guys, the project is finally started thought i'd give an update!
The old 1.4 fsi engine is out now, im looking to sell it with ecu, gearbox etc, anyone know how much i could get for it? its got 45,000 & Full Vdub history.
Heres the rundown of parts i needed for my 280hp (hopefully) polo:

AYP 1.8t from Seat ibiza
02J Gearbox from Ibiza 5speed
Drive shafts from new skoda fabia TDI
K04-023 turbo, Manifold & pressure Pipe from Audi TT 225.
Custom Intercooler & Turbo inlet pipes
Injectors, 4bar FPR & fuel pump from Audi TT 225
3" MAF housing
Engine Mounts, Gearbox Mounts (OEM from VW)
Engine Support Brackets & console (OEM from VW)
Turbo Oil lines extended to fit because of K04
Front Mount Intercooler - 530 x 234 x 65 mm
Blitz Super sound BOV
3" Blueflame Custom D/P & Exhaust - from Turbo to Back
LINK G3 Stand Alone ECU & display link.

I was originally getting a plug and play ecu, but after ordering I was told its not quite plug n play on the 9N! The engine would run fine but all the tachos in the dash wouldn't & i would have to either get a polo GTI EMS or new LCR EMS or run extra gauges. I wanted a clean standard looking install & didnt want to change my dash, this was a big problem because the only reason I was doing the conversion was because it seemed easy (wrong!).
Then I was really regretting not taking the clocks, keys, ign barrel, ecu, etc from the donor car and I guess alot of people will think I should have gone that route in the first place, but now I am getting a stand alone ecu which can control everything (except VAG diagnostics), I found Thor racing who said they can help me out, The ECU will hook up to everything in the car so I dont have to change any clocks & it comes with a display link (small screen) which tells you everything.
I managed to grab a bargain off ebay for the K04 turbo & manifold last week (£285 & in excellent cond) so I had to get that which ment also getting a few extra bits like the fpr, maf etc.
Im waiting for my parts from VW, should be here on tuesday, then i can get the engine in place!
Then I Will be getting the car towed to BlueFlame for my Exhaust then to THOR Racing to get the ECU fitted & a day on the rollers mapping. Hoping to see 290hp, but i'll be happy with 250 to be honest!
All in the project is costing me £4250... if everything works I saved £3000 rather than paying another company & I have a standalone ecu.
Will be adding photos soon....watch this space!
Looking to race you seat drivers soon, I been taken by them for far too long!
Thanks for reading... any opinions much appreciated!

 

[Craig!]

If your after engine mounts I've got a full set of OEM ones here, used but still perfectly fine and no doubt £200 cheaper than VW!

 

[acidstrato]

quite an adventure, should be pretty nippy when done, and still very comfortable.
but what i dont get is your gonna run stand alone management with a maf and a bov??? would it not be better to ditch the bosch maf altogether?

i do agree with what you said about just running the doner cars ecu etc would have saved time and money but no matter. looks like it'll be fine.

keep us updated

 

[str8ballin]

quite an adventure, should be pretty nippy when done, and still very comfortable.
but what i dont get is your gonna run stand alone management with a maf and a bov??? would it not be better to ditch the bosch maf altogether?

i do agree with what you said about just running the doner cars ecu etc would have saved time and money but no matter. looks like it'll be fine.

keep us updated

Hi there, Yes your right I think they are going the ditch the MAF but im not 100% sure. I will leave all the electricals to them it gives me a headache!

Thanks!

 

[str8ballin]

If your after engine mounts I've got a full set of OEM ones here, used but still perfectly fine and no doubt £200 cheaper than VW!

Hi craig, Which engine mounts have you got? can u tell me the part numbers please mate.
Cheers!

 

[ibizacupra]

Link G3 ecu... supports drive by wire yea? got any more info or links?

 

[Craig!]

I've got all three, front engine, rear engine, gearbox off an AQX/AYP Ibiza, I can get the codes off them if you want?

 

[HarveyGTI]

Looking to race you seat drivers soon, I been taken by them for far too long!
Thanks for reading... any opinions much appreciated!

great project and always good to be different.....

but one thing always sticks out to me, if you are looking to "race" and beat Seat drivers, why didn't you save the £4000 spent on the conversion and put it on something like an Audi S3/4 or something equivalent

insurance would be cheaper right

anyhow, who cares! looking forward to the pics

two things to finish the car off nicely....BBS deep dish rims and slammed

 

[str8ballin]

Link G3 ecu... supports drive by wire yea? got any more info or links?

www.linkecu.com/ its the G3 model

Hi mate, I just rang them now to make sure drive by wire works... i hadnt thought about it!!! But yea its fine, The Link G3 ECU apparantly can control any functions on the new cars.
I think the ecu is around £600, they quoted me £1200 inc fitting, extra sensors or connections required and full days mapping.

www.linkecu.com/ its the G3 model

The LEMG3 is a very flexible, powerful engine management system. It is configurable to suit almost all applications.

Use your factory idle speed hardware (stepper, solenoid - no problem)
Precision 3D boost control that is superior to stand alone after-market electronic boost controllers with air and engine temperature compensation
Capable of running everything from distributed engines through to eight coil V8's
USB on board for direct connection to your laptop
Absolute stability of tune regardless of altitude and daily changes thanks to the on-board, barometric sensor
Run your multi butterfly (NA or boosted) engine with confidence by selecting 4D fuel mapping
Keep your LEM firmware (the software the ECU runs) up to date with free downloads from www.linkecu.com
Select the engine you want to using the factory triggering from the LEMG3's digital set-up menu
Lots of spare "in & out" wires to give you the flexibility you need for fans, pumps, switches, lights etc.
Plug the DisplayLink straight in for instant results
The LEMG3 arrives fully optioned, use the features you want
The open 2m loom is included
Mounting brackets are supplied
PCLink works immediatly after installation
LEMG3 starts "out of the box" using base start up maps that are a good starting point for dyno tuning.
Group or staged injection, you choose
Add a "pot" to give the driver the option of reducing boost or a switch to select another boost map
Switched dual mapping for different fuels
Dual maps to optimise switched cams (VTEC)
4 MB data logging on board (to be enabled by firmware upgrade later)
Compatible with the excellent, cost effective, Innovate LC1 "wide-band" sensor and controller
Limits galore to protect your engine
Temperature stable engine tuning thanks to the essential inlet air temperature sensor sold separately
"Rocket fast" 40 MHz microprocessor for "rock solid" control up to 20,000 rpm
Huge fuel and ignition maps (if required) with 0.1 resolution that you can define
Cold start your engine "better than factory"
Control your nitrous or water injection in real time 3d tables
Motor-sport proven anti-lag, launch and flat shifting
Run up to 1.5 bar of boost (22 lbs)
If you want to keep it really simple you can use the LEMG3 just to control your fuel and ignition or go full house and use all the features, it is totally up to you.
DETAILED SPECIFICATION
Engine Configurations:

2-12 Cylinder Distributed
2-8 Cylinder Wasted Spark
2-4 Cylinder Direct Spark
1-2 Rotor
User Configurable Firing Order
Fueling Adjustments:

Up to 440 Zone Fuel Table with configurable load and RPM centres. MGP, MAP and load options.
Dual Fuel Tables
Up to 4D Fuel Mapping
Injection Rate
Master Enrichment
Pre Crank Prime
Crank Enrichment
Post Start Enrichment
Warm Up Enrichment
Acceleration Enrichment
IAT Fuel Correction
Injector Deadtime
Overrun Fuel Cut
Idle Load Trims
Fuel Temperature Correction
Ignition Adjustments:

Crank Dwell Extension
Maximum Advance
Spark Duration
Dwell Time
Up to 440 Zone Ignition Table with configurable load and RPM centres. MGP, MAP and TPS load options.
Dual Ignition Tables
Up to 4D Ignition Mapping
Individual Cylinder Ignition Trim
IAT Trim
ECT Trim
Limits:

Engine Temperature Dependent Soft and Hard RPM Limit
Engine Temperature Dependent Soft and Hard Boost Limit
Vehicle Speed Limit
System Voltage Limit
Triggering:

Digital Trigger Decoding
Choose from configurable trigger patterns or preset triggering
Processing:

40 MHz Specialised Automotive Microprocessor
Ignition control to 0.1 degree, fuel to 0.01 ms
32 Bit Calculation
10 Bit ADC Resolution
Max 20000 RPM
Inputs/Outputs

2 High Current Injector Drives
4 Ignition Channels
8 Auxiliary Outputs
1 Digital Input
+5V Out
+8V Out
2 Temperature Inputs
2 0-5V Analog Inputs
2 Trigger Signal Inputs (Reluctor, Optical or Hall Sensors)
Internal MAP Sensor (2.5 Bar Absolute)
Communications:

On Board USB (Tuning Port)
Serial
CAN Bus
Analog Inputs:

Wideband O2 (from external controller)
Boost Adjust Signal
Voltage (0-5V)
Pyro (from external controller)
General Purpose Pressure
Boost Control:

Open or Closed Loop
Engine Temp Correction
IAT Correction
Dual Boost Tables
Idle Control:

Open or Closed Loop
Solenoid or Stepper Motor ISC Valve
Aircon, Engine Fan or Power Steer idle up
Temperature Inputs:

Custom or preset temperature sensors (IAT, ECT, Fuel Temp. or General Purpose Temp.)

MotorSport Features:

Antilag (Group N and Group A modes)
Launch/Traction Control
Flat Shifting
Auxiliary Output Options:

General Purpose Output
General Purpose PWM
Idle Speed Control (Solenoid or Stepper)
Fuel Pump
Fuel Pump Speed Control
Engine Fan
Air Con Clutch
Air Con Fan
Intercooler Spray
Tacho
Check Engine Light
Purge Solenoid
Additional Accessories (Purchased Separately):

Intake Air Temperature Sensor
Throttle Position Sensor
1,2 or 3 Channel Link Igniter
Wideband O2 Controller
Injector Ballast Resistor Packs

 

[ibizacupra]

I've found their website and ity does'nt mentioned it supports drive by wire on there...... you sure?
idle control via stepper is'nt drive by wire.

This outfit familiar with VAG cars?

 

[str8ballin]

I could've just got an S3 for the money im spending and if i sold my car but its all about the element of suprise...U know you wouldnt expect to get left by a polo, but then the look on peoples eyes when its gone...... priceless!!
Will be adding photos this evening hopefully.
cheers

 

[str8ballin]

I've found their website and ity does'nt mentioned it supports drive by wire on there...... you sure?
idle control via stepper is'nt drive by wire.

This outfit familiar with VAG cars?

I just phoned up Thor Racing on 0845 2605760, and they said the G3 is compatible with drive by wire.
To be honest I would prefer cable throttle anyway and if it doesnt work it costs £50 to convert to cable throttle.
QPENG sell the kit, £50 +VAT

Does anyone feel that slight delay in response with drive by wire???

thanks

 

[Craig!]

And I still won't be left by a Polo, and neither will Bill haha!

 

[Saul]

but they do make a polo gti 1.8t ?

 

[JIMYU]

theres a guy on vag20v.net with a 1.8t polo...might be useful for you

 

[Forbez]

Good luck mate i've seen a few of these and mighty impressed with them, Good on you.

 

[rashcupra]

cant wait to see the results keep the pics and parts lists coming! if you do get the 3" maf housing ul need the diesel airbox lid to fit it too! will be a sigt seeing the looks on ppl's faces! definatly get coilovers and spacers and a set of 16's - 17's

 

[ibizacupra]

I just phoned up Thor Racing on 0845 2605760, and they said the G3 is compatible with drive by wire.
To be honest I would prefer cable throttle anyway and if it doesnt work it costs £50 to convert to cable throttle.
QPENG sell the kit, £50 +VAT

Does anyone feel that slight delay in response with drive by wire???

thanks

there's no delay in dbw...

 

[str8ballin]

Thanks guys for the feedback! I get the best response on this forum, more than the uk-polo & vw forums!
I've been planning this ever since I got my polo in 2003, but the warranty holded me back!
I'll give an update with photos on tuesday once we start gettin that engine in!
Cheers

 

[ibizacupra]

I just phoned up Thor Racing on 0845 2605760, and they said the G3 is compatible with drive by wire.
To be honest I would prefer cable throttle anyway and if it doesnt work it costs £50 to convert to cable throttle.
QPENG sell the kit, £50 +VAT

Does anyone feel that slight delay in response with drive by wire???

thanks

ok, thanks for checking.. their website does'nt say its dbw, only stepper motor/idle control.
is this going to run the whole motor complete etc?
not piggy backing at all.