Installing a turbine on a Polo Sedan

REVO ST2+ (ST3) I did it!

Yes yes yes. I made up my mind to do this adventurous act! I will not show off and say it is st3. Because of the alterations only a turbine from a similar engine and soft, so modestly st2+. Introduction. About the installation of the turbine from 140/150 power Vag I learned a long time ago, but for some reason for 2 years of owning a car about this tuning no information has not collected. There are rumors, there are owners who had it was so temporary solution that they do not remember anything, myths, etc. )) But somehow it stuck with me very strongly and never came out of their heads. The idea that you can put a bigger turbine and without a lot of modifications and money to get 180-190 hp and more than 300 torque, almost maintaining engine life did not give me peace of mind. Seems like the last half a year or more I buried these thoughts, firstly REVO a year ago made it clear that they will not do more than st2 and do not want to take up st3, secondly there is really little information, and why take the risk… Until recently, when several events coincided: My car wasn’t driving (well, plugs are dead, read the previous post), my teammate burped a turbine and he was considering options for replacement (stock or non-stock) called Revo to clarify information about the chip and found out that they are ready to stick and flash a 150 strong turbine. I could not stand it and called REVO and was told: not recommended at all, but if the turbine is new and you want it, yes, we can! From that moment there was no turning back, as my fart was burning like never before

Turbine selection. The hardest part. I will tell you everything I have learned and understood. If I’m wrong somewhere, correct me. I repeat that the information normal is really little and it is contradictory. Few reviews and information as it all serves, as either sold cars or people have gone on to the IS12. And basically someone once told someone and information spread through all the forums … and where are the proofs? – no)) There are two turbos installed on 150hp engines. IHI and MHI. The first myth: it belches out from 150hp octah, and not from 140hp jetta, because the shaft is thicker in jetta…We find out that MHI is installed on octahas and IHI on jettas. What is the difference, that one goes belch and the other goes? I had to scour the forums of the owners of schooldochs to find a real comparison of these turbines. The main difference is the actuators, they are slightly different principles and sort of different companies. One of them (on MHI) as I understand with mechanical rod adjustment. And the second difference is in the hot part of the turbine. But the cartridge on both turbos is the same! Absolutely. I found a photo with measurements, someone even has one on the drive. From what I understand the cartridge fits any turbo. So forget about the “thicker shaft”. Got it. Moving on. Here’s a correction. Everyone write that the only difference between our CZCA engines and the 150hp ones is the turbine and the presence of a second phase shifter. But, I’ve read on the forums that the heat exchangers are different too, it’s a little more advanced on Octahas, so our engines have turbos from Octavias overheating and belching. That actually seems to be true. But since I couldn’t find any information, I settled on the general consensus about the difference in turbines. There is more. For me personally I decided that there is no difference what company to take the turbine. I started to look through the part numbers, and there are… fuck. That’s for fuck so many articles) what are the differences? Again, Yandex and drive helped. I found out about the revisions of turbines and the differences in the last letters. I started my search for a turbine with Avito, but luckily the sellers were honest and I did not “steal” any ruined parts. The problem is that the mechanicals can be checked for backlash, but there is no way to check the actuator. And they are the weak spot on both our stock turbine and the 150 hp one. You can buy the actuator separately but it needs to be adjusted at the dealer equipment. And how long the shaft will work out is also unknown. In general why this lottery. So buy a new one. Took me a month to buy if not more. Prices horse . Depending on the revision, the price difference is two or more times. After looking through all the possible revisions and options, I found the cheapest one: 04E145721B. IHI. And I put it in the cart on various sites, watching the price dynamics of this turbine and the proposed “analogues”. In quotes because there are no analogs, there are only turbines of another revision with a different article number or factory remanufactured. Also I immediately ordered the installation kit of gaskets Jp group 1117756210. It is a must, the gaskets are disposable. After a month of searching, finally got a budget price. I had to reorder several times, there were refusals, type out of stock, but after 3 times I got it and took the new set from the store and here’s the surprise! Really predictable. The latest 04e145721f turbine is here! Well great! Didn’t overpay either!

Installing ESP on Polo Sedan

Nuances of installing a turbine on a Volkswagen Polo sedan

Anyone who has ever been on a real international motor-racing track and watched the racing battle of professional pilots will never forget the screeching roar of the power plants of the cars. When just one car rushes along the track, your ears start to pop. But when a stream of “charged” cars flies along the track, the usual roar turns into a monstrous storm.

The turbocharger is to blame. Alfred Bühi, the Swiss engineer who patented the first turbocharged device, once thought: “These ‘gizmos’ are so big and heavy and yet they don’t develop much power. The question asked itself: how to increase the performance of the power unit?

Racing cars

The basis of the invention was a windmill. The main component was the turbine rotor. It was a small wheel with numerous blades, which were driven by the exhaust gases. The compressor, on which the rotor sat, acted as a fan – pumping additional air into the cylinders. To allow more oxygen to be released, the unit was equipped with an intercooler that cooled the air entering the system.

To take a ride in a car with a turbocharged engine, it is not necessary to sit behind the wheel of a race car. Today, many modern cars are equipped with turbocharged power units. And we are not talking about expensive sports prototypes, but about ordinary cars, which many motorists can afford. Another thing is if the car is already bought and there is no turbo on it. How then to realize your ambitions? After all, everyone at least once in his life dreamed to feel like a real racer.

The turbine's device

Volkswagen Polo sedan: many motorists liked this “iron horse”, collected by our masters in Kaluga. Everything in it is arranged harmoniously: a stylish design, and cozy interior, and a powerful duet of the motor with a transmission. Such a successful combination of characteristics makes you want to make your car even better. Therefore, many poloveds are engaged in tuning of the German sedan.

Gas equipment on the Volkswagen Polo sedan

A large category of owners often ask questions on forums about increasing the power unit and acceleration characteristics of the Polo sedan. The 1,6-liter “atmospheric” with the capacity of 105 h.p. accelerates a car up to “hundred” in about 10,5 seconds on “mechanics”. What to do to improve the indicator?

Ways to increase engine power

Of course, there are a lot of variants. “Games” with the aerodynamics of the car – spoilers and various dodgers, replacement of the standard suspension with a sports device, “re-shoeing” on racing tires, reducing the weight of the body by dismantling certain parts – all this will accelerate the Polo sedan. However, the speed increase will be insignificant. At most one second will be removed. Many owners will be satisfied with such result.

Tuned Polo sedan

But others will not stop there and try other ways. For example, to increase the engine volume. It is a hard way, requiring deep intervention and good knowledge of the engine’s device. If you know the “heart” of your car perfectly and are confident in your abilities, you can bore the cylinders or exchange the crankshaft for a new sample with a larger crank-crank radius. However, even experienced motorists are advised to seek professional advice when performing the operation.

You can also work on the cylinder heads: bore “seats” for valves with increased diameter, install a more powerful camshaft and split pinion. Together with worked out intake and exhaust manifolds the result will be more than striking. And if you “pump” the throttle, put a zero air filter and a fresh “engine” control unit, the power unit of the Polo sedan will increase even more.

Finally, the most effective method of increasing the efficiency of the internal combustion engine of the “German” is the installation of a turbocharger in the system. German motors, in particular those produced by Volkswagen, according to many experts, are a good basis for strengthening the dynamic parameters of the car. The Jetta and Passat are excellent examples of this. The consumer can make a choice in favor of a conventional atmospheric engine or buy a model with a turbocharged engine.

For some time, the Polo sedan was equipped only with a standard gasoline engine. But now from the beginning of 2016 Russian motorists have a chance to buy a model with a turbocharger, which increased the power of the power unit by 20 hp Total – 125 “horses” under the hood of the German sedan.

Installed compressor

The news is certainly pleasant for fans of the German car industry. But what should the owners of standard Polo sedan do? The salon centers of official dealers do not install turbines. Only a few professional masters practice such innovation in homemade conditions. And then such manipulations can allow only those owners whose cars have been waiting for an overhaul of the iron “stuffing” for a long time.

Activating Polo Sedan's extra features

Peculiarities of turbine installation

To modernize the engine, whether gasoline or diesel, you will need not only the turbine itself, but also a special exhaust manifold with a flange. It will increase the transfer of exhaust gases and add horsepower and torque.

Before installing the turbine, you should prepare the engine for the procedure. It is mandatory to put new oil and air filters, as well as change the engine oil. The priority is to check all the pipes that entangle the system. Lack of tightness in hoses or their damage can negatively affect the operation of the power plant.

Intake manifold

The next step is to clean the breather valve. “The breather valve,” which keeps the crankcase’s internal pressure balanced against the external pressure, should shine clean. Otherwise it can cause the entire system to clog. Then the compressor comes into play. Using a syringe, oil is pumped through a special hole. This must be done to lubricate all moving parts of the device. Without lubrication, the mechanisms will quickly heat up and wear out. Finally, we check the position of the oil pipeline – it must stand vertically and mount the turbine on the engine of the “German”.

The positive side of such tuning on the Polo sedan is the increased performance of the power unit of the car. But modernization also has its pitfalls.

The biggest “stone” is the reduction of the engine life. To squeeze out the maximum from the “engine” without consequences? There is no such a thing. Besides the turbocharged motor will have to be serviced much more often and to use more expensive expendable materials. The standard oil will not work here, you will have to buy the German original working fluid (VW 501 01, VW 502 00, VW 503 00 or VW 504 00). The same concerns the fuel – you should refuse from cheap AI-92 and AI-95 and switch to gasoline with a higher octane number.

Fog lights on Polo Sedan with my own hands

And the last thing: it is necessary to clearly understand that the upgrade of the engine with a turbine can cause certain complications in separate units, which can turn into expensive repair of the main organ of the sedan.

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