I5 and slushbox: what power can one get? (similar to 1.8T rel. thread)

[Gerard <gerard@poboxes.com>]

Hi!

Just looking at the thread about the 1.8T reliability. Interesting
stuff. Thought I might as well get one going for the older 5 cylinder
motors. I'm sure this has been done before.

Ok, here is the setup: 1990 200T (uhm, only a few problems with it
now, like trying to brake) fitted with the 3-speed auto tranny,
boost is still stock at 1.4 bar, ECU is a MAC-13 but local VW/Audi
techy tells me the lambda unit was removed as we did not have unleaded
fuel back in 1990. Engine is MC. Completely stock 2.2 turbo unit, but
I don't know the full compression ratio, I still need to get round
to comparing engine/model numbers with the info that was recently
supplied on this list.

Ok, the questions: what is the suggested mods for this motor? These
include ECU (including % change to fuel-pump cutoff values and changes
to electronically controlled (??) boost), air intake, exhaust,
braking, protective coatings, air ducting, inter-cooler, hosing
(including the "Michellin Man"-tube and brake-hosing).

Also, I'd like to know who of  you out there is running mods on an MC
and what power output you're getting. And how about 0-60MPH timing
and top-end readings? :)

Mods I have lined-up for the future: air-box change to either TAP
5000T cone conversion or JAMEX K-Jet box replacement (if they send
more info), ECU remap for cut-off levels and boosting (when I finally
get a new MAC-13 ECU as a spare), exhaust change to 2.5 inch from 2.25
fitting Borla XR-1 Oval and XR-1 Bullet mufflers and 2.5 inch to 3 inch
dual-pipe tailpiece, replace currently buggered brakes with drilled
Brembos and 4-piston calipers, fit new aluminium intercooler and
radiator, renew all brake hosing and vacuum lines for steel braids and
thicker rubber tubing, JAMEX or TAP stress bars (rear and front,
JAMEX seems to be more readily available here), JAMEX adjustable
shocks with ride-height control additions (U-SET-IT from TAP),
new bump stops, blow-off (blow-by) valve, BRISK Premium spark plugs,
ceramic coating on headers, intake manifold and turbo, perhaps also
on entire length of exhaust, ignition leads. (And that's definitely in
no particular order).

As for the ECU mods, anybody running 1.8 bar on a slushbox? If the
air intake is modified to the TAP or JAMEX does the ECU need
remaps for this?

As for turbo system, will keep it stock, but I'm collecting the info
to fit a Q-List closed-loop blow-off valve. I want to coat it in
a protective ceramic coating that I looked up about a month ago when
ceramics was being discussed on the list. Anyone ever polished the
blades on the turbo? Supposedly there is a bang of power available
from having the turbine fins polished.

As for the braking system, I just decided on Brembo rotors as they're
the only name that immediately springs to mind. Anyone running different
calipers from stock? Who is this list's recommended manufacturer or
replacement steel braid brake lines?

As for exhaust system, I'm dead-set on the Borla stuff going by the
good info I got from this list. I am going to import the ceramic
coating for the headers, these help reduce engine bay temperatures by
up to 100F while keeping the heat in the exhaust system where is
is needed. That's the reasoning behind coating the entire length of
the exhaust system, but I might be being stupid about that.

As for ignition system, I'm going to get what this list suggested:
Blue Ignitors. Also, I will be ordering those BRISK Premium spark plugs
just as a test unit.

As for stress bars, what is available out there? Once again, I'm
looking at JAMEX for availability.

As for shocks, looks like it is going to be the JAMEX thing again.
I only discovered today that they make adjustable systems. I'd love
a set of Koni, but they're asking 1/7  the value of my car for them
and then they're those that were specified for the A6. How does the
U-SET-IT ride-height control thing work? Anyone using it? If I get
favourable information on AVO shocks then I might be going that way.

As for cooling system, who is running a fully aluminium radiator?
I will probably not replace the intercooler, but if I do then what
should I be looking out for? Anything out there that is recommended
besides TAP aluminium intercooler? What about hosing?

Other mods lined up: Pioneer stereo. :) (Oh God, look at that! The
head unit and the equaliser are the same price as a set of Konis!!)

Other questions: anyone running aluminium spacers on the wheels? Some
guy told me they help, but I don't feel they can be very safe. Besides,
these 200 machines are damn wide anyway.

Oh yes, rubber-feet, Bridgestone 205/65/VR15 (same as factory spec).
I think those aught to be enough to keep one on the road. Besides,
don't really want to drop the car by 40mm, fit wide shoes only to
discover my body panels coming off and the only direction is straight.
:) Also, the local mentality is: nice mags must make the car go real
fast!!!

I'd appreciate comments and criticisms and better ideas. I know I still
have some posts floating around this list about things that need
fixing on my car before I can even consider mods, but I might as well
start planning now. :) Also real curious as to what sort of power
people are getting from these 2.2 I5 MC turbo FWD auto tranny
machines. Also comments on what else to change to hold any new power,
especially propshafts and CV joints and other bearings.

Thanks.

G.
-- 
"a thousand miles from here, there is another person smiling"
1990 Turbo (200T)
name   : gerard van vught
tel    : +27-57-912 2658 (w) / 082 923 9609 (cell)
url    : http://www.acenet.co.za/homepages/gerard/
e-mail : gerard@poboxes.com  / han.solo@galaxycorp.com
         gerard@acenet.co.za / van_vught@frg.issi.co.za