TSI - Supercharger cover removal DIY

[POLARBEAR666]

You can do this mod by just jacking up front tyres quite high.
Get under the car, reach your hand up past the driveshaft on right hand side of the car (drivers side). Just unclip the 2 tabs at the bottom and one at the top that is a bit of a pain to reach but u will get there.

Then you have 2 choices:
1. Just pull the foam out and then reclip the plastic cover in place so nobody would ever know the insulation is gone.
2. Grab a soldering iron or dremel and cut through the plastic cover into 2 bits so you can pull it out through the gap at bottom of the car.

NB: you may need to unclip the one sensor that is hanging in the gap that goes from the gearbox. Just pull on the metal tab it is supported by and it will pop loose from the subframe and you can position it out of the way.

Some lead, others follow. :driver:

**Do this at your own risk**
http://www.vwwatercooled.com.au/forums/images/imported/2009/05/P5300024-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2009/05/P5300023-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2009/05/P5300025-2.jpg

2 FULL POLAR MOD: Polar, Creniac
1 HALF POLAR MOD:Paul_OH, Sreay

[Creniac]

I like it!!! like you say, I would also think it will hold unwanted heat around the charger......

[POLARBEAR666]

cheers..

The heat foam and cover negate the factory heat fins that are all over the supercharger from eaton. I figure my intake temps should drop particularly when the car is moving and cool air is running over the charger's fins.

Most importantly, it should sound like I am running one of these. (NB: yes that is a supercharger off a freight train, no it isn't photochopped)
http://www.classicnation.com/pictures/images/car_shows/classic_cars/supercharger.jpg

[G-rig]

How about some before and after dynos?

[tinto]

Have you had a chance to check out the temp differences on the scanguage?
Does it crank up the SC sound to freight-train status? :)

Bloody Cogdoc is a baaaaad influence ;)

A couple of other questions...
If you remove this particular shield, is it not the opposite effect you've achieved by wrapping the turbo up front?
Or are you more concerned about the air temps going through the SC than any heat radiated into the engine bay?
or is radiant heat less of a concern due to the location of the SC?

I'd be interested to see if there's any effect on intake air and general engine bay temps. Nice work Polar.

[Paul_OH]

Most importantly, what's it sound like? :cool46:

Did you access this from the drivers side rear of the block?

[Greg Roles]

What a great idea......Hip Hip hooray!!!

All that insulation does is keep the car quiet for the wowsers. There's no good reason to heat up intake air unecessarily, except perhaps warmup in cold countries.

10 man cards to you Polar!:bowdown: Despite all the flack you cop from people at times, at least you actually do more than TYPE!

Tinto you wrap the turbo as you have exhaust temps going through it. Great idea to keep that inside the turbo AND you want the exhaust gas to retain as much energy as possible to turn the turbine. You only have intake air running through a SC, and it's the fact it heats the intake air up that's the problem. It's going to be a whole lot less hot than the turbo / exhaust combo, and I can't see the rear, low location being a problem for inlets, even after idle for a few mins. Certainly much less than keeping the air passing through a hot item once underway. Why do you think you never see a V8 supercharger wrapped??

Polar's car will undoubtably sound awesome AND the response, especially once it normally gets hot in traffic will likely be much better. I'd expect the low to mid torque to be better but overall power is still limited by the ECU G-rig.

This is one instance where it's all gonna be about seat of the pant, let alone using the ears!!

I'm ALMOST impressed with the TSI gang now...:biggrin:

[POLARBEAR666]

Cogdoc is correct, as it is sucking ambient air, you don't need to worry about wrapping it and in fact it heats the air so you want it getting as much cold airflow around it as possible. The position down and low near rear of engine bay will have tonnes of air rushing past which will suck hot air out.

You can do this mod by just jacking up front tyres quite high.

Get under the car, reach your hand up past the driveshaft on right hand side of the car (drivers side). Just unclip the 2 tabs at the bottom and one at the top that is a bit of a pain to reach but u will get there.

Then you have 2 choices:

1. Just pull the foam out and then reclip the plastic cover in place so nobody would ever know the insulation is gone.

2. Grab a soldering iron or dremel and cut through the plastic cover into 2 bits so you can pull it out through the gap at bottom of the car.

NB: you may need to unclip the one sensor that is hanging in the gap that goes from the gearbox. Just pull on the metal tab it is supported by and it will pop loose from the subframe and you can position it out of the way.

[Paul_OH]

Excellent Polar, luv ya work. I think I know what I'm doing this afternoon. And my GOD, you've almost impressed Cogdoc :nana:

I can also add that the foam is shown as 'noise insulation' (not thermal) according to the TSI document provided by Greg.

[POLARBEAR666]

By the way for those attempting this... once you get the plastic shell free, you really can't go wrong. Just rip at the foam till it all comes out. You can also reach from above in the engine bay to get an angle on some of it.

The shell is very tough, so once your finished stuffing around with the foam you can just clip it back into place easily; but I prefer to cut it out and let the superchargers aluminum fins do some work getting rid of heat.

If you look at the pictures 2 posts up you will get a better idea of where I was working and also you can just see the sensor cable that I moved in the picture. You will know which one it is when your under the car.

[Paul_OH]

But how's it sound??? :javacomputer:

[POLARBEAR666]

I have an exhaust and a BOV so its fairly noisy car when you floor it.

But the whine is very defined now. I tried taking a video but all the sounds blend together on the video and you can't really make it out. IRL it is a very distinct and sharp supercharger whine sound. Nice but without being SUPER loud.

Just sounds like you definitely have a supercharger.

[Paul_OH]

And done! I left the plastic cover in place though as access is a bitch and it looks standard from the outside. Absolutely filthy so haven't taken it for a drive yet but will report back from a relatively stock (other than CAI) point of view.
After jacking the car and getting stands in place it only took 10 min or so, it would definitely pay to have petite hands and arms though.

Well done Polar for the DIY. Many apologies to cogdoc for not doing this 11 months ago as strongly suggested :wasntme:

[M4RK0]

I have an exhaust and a BOV so its fairly noisy car when you floor it.

But the whine is very defined now. I tried taking a video but all the sounds blend together on the video and you can't really make it out. IRL it is a very distinct and sharp supercharger whine sound. Nice but without being SUPER loud.

Just sounds like you definitely have a supercharger.

Hi Polarbear, I don't know much about your mod, reading the opinions it's about sound? or performance?, give to the car more sport sound? :driver:

You are taking off the cover, what about the water when rains?, it's that a risk?,

Cheers!!

[nayfen]

http://www.forumammo.com/cpg/albums/userpics/10062/BoloYeungMore.jpg

[POLARBEAR666]

Hi Polarbear, I don't know much about your mod, reading the opinions it's about sound? or performance?, give to the car more sport sound? :driver:

You are taking off the cover, what about the water when rains?, it's that a risk?,

Cheers!!

HEHE Love the MOAR picture above...BOLO from bloodsport! He was my inspiration for doing weights... so that I could make my pecs go up and down like he does.

On topic - It is about removing unnecessary heat insulation around a supercharger that is designed to be open to the air normally. They even have heat fins all over the housing to get rid of heat. It is both performance and sound. It is noisier but it also will run cooler this way and will probably be a fair bit cooler on cold days. Colder boost = lower exhaust gas temps and better engine longevity.

Its location is right near the airstream that exits the engine bay, so the aluminium fins on the supercharger housing will be dissipating heat constantly. I will be monitoring my average variance between AMBIENT and INTAKE air temps and will report back. It used to be 10-12 degrees stock.. it was around 6-7 after my last batch of mods.. I think it is now 5.

[BarneyBoy]

Good job, Polar! :cool46:

Since it IS only sound insulation, there shouldn't be any heat issues.
I agree, it's designed to NOT be smothered, so off it should go!

Maybe this is the TSI equivalent of the R32 Flapper Mod? :biggrin:

[POLARBEAR666]

When you handle the foam... I don't see how it could be called just SOUND insulation. It is very very very dense foam. It would keep me warm in winter that's for sure!

I think they say sound insulation just because they want to ignore its negative aspects regarding heat.

[Guest212]

HEHE Love the MOAR picture above...BOLO from bloodsport! He was my inspiration for doing weights... so that I could make my pecs go up and down like he does.
.


Now you need to go on a diet and ditch muscle mass.

can't have that useless meat adding to the weight of the vehicle.

have you considered throwing up before driving it?

every gram adds up hahaha

ps: :nana:

[Greg Roles]

Ribs are more to do with structural reinforcing, can't have any flex with such tight rotor / body tolerances, but I'm sure they help dissipate heat somewhat.

Perhaps the next step is sticking a few Peltier devices on the blower body, and making it into a cooling device! I have my eye on these babies, just need flat surfaces to stick them on. Jaycar have three sizes. If your new to these, basically one side gets hot, causing the other side to get equally cold when current is applied.

http://www.jaycar.com.au/productView.asp?ID=ZP9104&keywords=peltier&form=KEYWORD

[Greg Roles]

.

Well done Polar for the DIY. Many apologies to cogdoc for not doing this 11 months ago as strongly suggested :wasntme:

It's always tough being a herald.

[mrx]

I think they say sound insulation just because they want to ignore its negative aspects regarding heat.

They also call the stupid jockey wheel a, "weight saving wheel", rather than a cheapo space saver, which is a crock.

We all know there's a much better solution for that wheel if you're serious about saving weight, don't we? :biggrin:

[Greg Roles]

YEP, put the same weight of amp, sub and cable in it's place!

[G-rig]

Well is it still illegal not to have a spare/space saver if the car came with one?

[Maverick]

Well is it still illegal not to have a spare/space saver if the car came with one?

Doesn't really matter unless you live at home and your Dad can deliver the spare wheel to you when you need it as not having it means the difference between getting on your way in ten minutes or spending ages stuffing around arranging assistance whilst your car is sitting on a flat tyre.

[nayfen]

^^^unless you have punched a coppa in the nuts and really p'ed him off do you think they are going to search your car in such detail just to hand out a warning or defect notice


Doesn't really matter unless you live at home and your Dad can deliver the spare wheel to you when you need it

or leave it on the side of the road and tell your daddy to buy you a new one.
thats what i would do!
plus i don't want to get dirty hands twice, once at the diesel pump and now on a spare wheel

[G-rig]

True Mav, but what about those pump & can of foam stuff? They would still weigh a few kg anyway?

[POLARBEAR666]

Last time i had a flat I just used the can of "Pump" in my glovebox... Walked to tyre (5 seconds). Attached nozzle (10 seconds). Sprayed the goo into tyre (1 minute). Then drove off home.

If you have never used a tyre filler can how can you comment that a spare is necessary. I drove more than 100km on the 'goo' filled tyre and when my wheel man took it off he said tyre sidewalls and everything else were still perfect. Wheels World did the swap. They do the porsche cup cars in perth and know what they are doing. they even stock DYMAG carbon rims there if you are super rich.

[Paul_OH]

Doesn't really matter unless you live at home and your Dad can deliver the spare wheel to you when you need it as not having it means the difference between getting on your way in ten minutes or spending ages stuffing around arranging assistance whilst your car is sitting on a flat tyre.

You should put smilies after your posts mav if you're having a laugh.
If not, then your little digs are becoming very tiresome. This is VWWC, if you're not contributing anything useful to a thread then start your :?own

[G-rig]

I was actually interested in the tyre foam stuff, as i'm still not sure if the legislation states you need a spare if the car came with one as standard.

Wouldn't mind saving a bit of weight too, but not sure most tyre shops would like cleaning out the crap from the tyre and would say you need a new one. (WIll have to ask bob jane again).

[tinto]

The Megane Sport 225 comes with a can of foam, not a spare.

Did Wheels World say anything about working with the goo, Polar?
I've heard some places get a bit shirty about it.... and the WW workshop is pretty clean :)

I think we've spoken about it before, but which brand do you use?

[POLARBEAR666]

i am pretty sure it was selley's Tyre PUMP. Other cars with can of tyre pump are Mazda MX5, Lotus Elise, Some euro's that have run flats like some BMW's.

The wheels world guys have been doing my cars for years. I probably dropped more than 10k there not counting tyres over the years.

They just commented that the tyre was in good condition.

[Maverick]

I was actually interested in the tyre foam stuff, as i'm still not sure if the legislation states you need a spare if the car came with one as standard.

Wouldn't mind saving a bit of weight too, but not sure most tyre shops would like cleaning out the crap from the tyre and would say you need a new one. (WIll have to ask bob jane again).

Most will charge extra and it's not worth using the tyre foam as you can cause more damage to the tyre by driving on what caused the puncture in the first place. You can't use it if you have in tyre TPMS either as it ruins the sensors. The spare tyre weighs ~15kg, makes bugger all difference at the end of the day and chances are you will get a puncture at some point.

If you want a lightweight car buying one that's lightweight from the factory rather than pulling bits off a Golf to try and make it lighter is a better way to go.

[Greg Roles]

You should put smilies after your posts mav if you're having a laugh.
If not, then your little digs are becoming very tiresome. This is VWWC, if you're not contributing anything useful to a thread then start your :?own

Every forum has a grinch Paul. I just accept it for what it is.

[G-rig]

Every forum has a grinch Paul. I just accept it for what it is.

Good not to take it too seriously all the time.

[Creniac]

Mine is up for a service soon, what do you think the VAG service boys would say if the cover was missing???? could it void warrantee?? or should I play dumb and say, "mate I have no idea, maust have fallen out somewhere".:wasntme:

[G-rig]

Why is it missing, what did you do?

[Creniac]

Rig, It's still there.....I want to take my supercharger cover off....I'm just curious if it could void warrantee if they see it missing?

[G-rig]

Oh, it may draw suspision but if they can't prove something is wrong or you don't have a claim, who gives a rat ar$e.

[Paul_OH]

You shouldn't have any issue at all, the VW technical manual lists it as insulation to reduce noise. As G-Rig stated above also, even if there were any issues with the engine/supercharger they would have to establish that it was caused specifically by the mod if they were trying to avoid a warranty claim.

Paul

[POLARBEAR666]

My car feels quicker down low... seeing the traction light a lot more.

I feel like the car is less heat soaked as my temp on the scanguage goes down quite fast after you get moving. Faster than it used too anyway.

[G-rig]

My car feels quicker down low... seeing the traction light a lot more.

I feel like the car is less heat soaked as my temp on the scanguage goes down quite fast after you get moving. Faster than it used too anyway.

Ha, good work polarbear, did you get the retune?

[Paul_OH]

seeing the traction light a lot more.


That's because it's been persisting down with rain for the last few days :nana:

I've noticed little/no difference in performance (didn't expect to) however the the SC noise is a little more obvious which is all I wanted anyway. Thanks for the DIY

[POLARBEAR666]

I have noticed a temp difference on my gauge. whenever it triest to get above 27.. it drops back down quickly... and even when its at 30 from sitting at lights the intake air temp will drop back down to 25-26 very quick now.. whereas it didnt really drop fast at all with the cover on.

Tune is probably going to be between 20-28th.

[G-rig]

I'm pretty sure it wouldn't make any difference.
(ie. the supercharger cover mod)

[tinto]

You shouldn't have any issue at all, the VW technical manual lists it as insulation to reduce noise.
I think your supercharger catching a cold (or worse, swine flu) is more than enough evidence to void your warranty. ;)

Speaking of intake temps, I drove home in 14C tonight.
Few things can beat the urgency of forced induction & cold weather. :)

[Greg Roles]

I'm pretty sure it wouldn't make any difference.
(ie. the supercharger cover mod)

To a car driven at speed and thus at normal temps, no probably not.

To a heat soaked car crawling in summer traffic, most definately. You just have to understand the theory of intake heat killing turbo car performance and it makes a whole lot of sence.

And as IF a VW tech would look that closely unless it actually went up on a hoist. Cars are pumped in and out at service departments, but if you're that worried about warranty, just leave it alone.

[Creniac]

Well it's done, my supercharger cover is completely removed!! unclips real quick and the soldering iron was called upon to split the cover for removal. Polarbear, I can definately hear the more defined sound..... me likes alot!!!

[POLARBEAR666]

Well it's done, my supercharger cover is completely removed!! unclips real quick and the soldering iron was called upon to split the cover for removal. Polarbear, I can definately hear the more defined sound..... me likes alot!!!

Good to hear.

So so far we have.

2 FULL POLAR MOD: Polar, Creniac
1 HALF POLAR MOD:Paul_OH

[Greg Roles]

OH, it's the POLAR mod then is it??

[BarneyBoy]

I smell a law lawsuit....
:brutal:
:biggrin:

[tinto]

Greg wants to split credit.
Bi-Polar.

[POLARBEAR666]

OH, it's the POLAR mod then is it??

YUP... its my DIY and I was first to do it. :nana:

[Greg Roles]

The glory is all yours watch boy.

[sreay]

would anyone like to post their video of the sound, i would really like to hear and might consider doing it to mine.

thanks

[POLARBEAR666]

The glory is all yours watch boy.

Dad says that hauling my mum must be killing your fuel economy
I say that your probably don't have enough torque to haul her!

[Fanaki]

hey guys, funny that this thread popped up again...

i attempted removing the sc foam yesterday but only managed to get half of the foam out and scratched the cr@p out of my arms!

does the sc cover fold all the way up (looking from the bottom)? i unclipped both the bottom clips, is there another i need to get to?

i'll be having a take 2 at getting the remaining foam out over the next few days.... at this stage i haven't really noticed any dif in sc sound.

thanks again polar ;)

[G-rig]

To a car driven at speed and thus at normal temps, no probably not.

To a heat soaked car crawling in summer traffic, most definately. You just have to understand the theory of intake heat killing turbo car performance and it makes a whole lot of sence.


You may as well copy him and take it off :rolleyes: :brutal:.
Sitting in traffic isn't that hard core, i'm sure VW have designed it to operate in a range of temperatures.

[Paul_OH]

does the sc cover fold all the way up (looking from the bottom)? i unclipped both the bottom clips, is there another i need to get to?


There's 2 clips at the bottom and I think 2 at the top, when all undone the cover can be totally detached and moved out of the way slightly so that the foam can be accessed all round. I too have the scratched arms to prove it, was looking like a self-harmer emo there for a bit! :rolleyes:

[Greg Roles]

Man up ladies.

Is that BOTH barrels then Polar?

[POLARBEAR666]

Man up ladies.

Is that BOTH barrels then Polar?

Yeah at the moment it is =0) I'm in a very good mood :banana: I'm 19 again if you know what I mean.

[sreay]

man took me while to reach the top clip but its now done, i decide to leave the cover in there though. there is the slight increase in whine sound might because i didn't remove the plastic cover anyways still sound nice than it was before. :banana:

:bowdown: polar

[POLARBEAR666]

Yeah I bet not having the foam significantly reduces heat soak ... In answer to some PM's I have had, you can remove cover as others have done, remove the foam and then reinstall the cover.

My fuel economy has got crazy good since cover was removed. This is around town driving not highway.
http://www.vwwatercooled.com.au/forums/images/imported/2009/08/13082009006-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2009/08/th_13082009004-1.jpg (http://s263.photobucket.com/albums/ii129/POLARBEAR666/TSI/?action=view&current=13082009004.jpg)

[sreay]

Good to hear.

So so far we have.

2 FULL POLAR MOD: Polar, Creniac
1 HALF POLAR MOD:Paul_OH

add me to the half polar

[sreay]

hey polar are u using a real BOV or a forge DV?

[POLARBEAR666]

Forge.. its an awesome bit of kit and reduces the thermal strain on your turbo as its not recirculating already hot air through itself to lower boost... EG goes in, goes out, goes in again, super hot, goes out, goes in again Super super hot.

[POLARBEAR666]

FEEDBACK:

After extensive testing at various speeds using my Scangauge 2. I have worked out that completely removing all heat shielding around the turbo assembly results in WAY cooler running than trying to contain the turbo's heat and stop other parts of engine warming up.

In cool weather like this the cold air rushing in front of car keeps intake temps within 5 degrees of ambient almost all the time.

Whereas when I had stock or my custom heat shield over turbo temps would be for example

Stock heat shield
18c outside.... 28c intake --- temp rises quickly from cold....water temp always at control point of 87.

No turbo cover
18c outside 22-24 intake -----temp struggles to get to 24... water temp does not reach 87 most of the time it sits at 85

[POLARBEAR666]

UPDATE: The other covers on the supercharger intake can be removed partially also at the back and they provide even more supercharger intake noise and cooling yay.

The bits to remove are the back sections of the two boxes that are before the supercharger and underneath the intake area. Again it is the same style of push clip arrangement that is easily dislodged. The bottom box holds the top shell from moving upwards so you need to dislodge the bottom cover to remove the top cover.

I only removed the back as I figure the front is protecting the pipes from heating up from the engine block. The backside however will have air rushing past it as it exits the back of the engine bay.

HERE:
http://www.vwwatercooled.com.au/forums/images/imported/2009/09/041-2.jpg

[sreay]

hey do the other 2 covers have foam in them like first main cover which is removed?

and how much louder is it or higher pitch sound are u getting

[Greg Roles]

Hey what a GREAT idea, why didn't I think of mentioning that?

You just SO rock Polar!:rolleyes:

One other glaring area of concern in my opinion is where the obviously hot exhaust below the cat (red ) passes / is bolted to the intercooler pipe ( blue ). That's an area crying for some insulation / separation!

[POLARBEAR666]

Hey what a GREAT idea, why didn't I think of mentioning that?

You just SO rock Polar!:rolleyes:

One other glaring area of concern in my opinion is where the obviously hot exhaust below the cat (red ) passes / is bolted to the intercooler pipe ( blue ). That's an area crying for some insulation / separation!

In answer to questions, the boxes have a thin bit of foam stuck to them unlike the main cover which had the very thick sheet.

I have not driven it yet but will report back on any sound difference.

The intercooler pipe definitely needs some exhaust header wrap but I have just not got round to it yet. It is a bit of a mission to get that pipe out so I don't want to do it until I have other reason's to jack the car up...

[GTom]

In answer to questions, the boxes have a thin bit of foam stuck to them unlike the main cover which had the very thick sheet.

I have not driven it yet but will report back on any sound difference.

The intercooler pipe definitely needs some exhaust header wrap but I have just not got round to it yet. It is a bit of a mission to get that pipe out so I don't want to do it until I have other reason's to jack the car up...

Change a wheel or 2 :biggrin:

Have the cover removal on my to do list!

[sreay]

hey any chances of photos of the covers and foam which you have removed and what the engine bay looks likes with out those 2 covers off.

thanks

[POLARBEAR666]

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P9070028-3.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P9070027-3.jpg

Charger sound is a little more noticeable.

I was thinking of running a cold air feed from front of car to the supercharger area so that cold air is running over it when moving.

[Prestianni]

About 14 years late but I’ve taken off the supercharger insulation on my 2016 Jetta.
Haven’t noticed a sound difference yet (I have a custom exhaust and a cts turbo intake so it’s hard to hear).
Haven’t taken off the intake covers but am thinking about that now too.