Tech Procedure: VW
Installing Neuspeed's 1.8t bolt-on kit
By Brendan Lopez
Photography: the author
It's been said that in the future everyone will be famous for 15 minutes, I believe that was an Andy Warhol'ism. If in the future everyone will be famous for 15 minutes, I suspect that at the rate things are progressing, in the future it will take 15 minutes to dramatically improve the performance and handling of one's car via dynamic electronics yet to be conceived. Today it takes a few hours, but who's counting.
In the old days, i.e. when I was growing up, to enhance the performance of one's car meant having to tear into the engine with reckless abandon, installing big cams, high compression pistons, porting the head and bolting on every conceivable go-fast part. These kids today have it so easy.
Celebrated and recognized as a "tuner's engine," the VAG (Volkswagen Audi Group) 1.8t engine can be tweaked from docile and meek, to a stunning example of the potential of tuning a tuner's engine.
The following article will show the details of how to install an integrated performance package on a 2001 GTI 1.8t from Neuspeed. Also, you can read the associated product review in the April, 2003 issue of ec.)
When undertaking the procedure, you will want to exercise proper safety procedures, keep a Bentley manual on hand, and leave the task to the pros if you feel you'll get lost.
To make things easier, we did the turbo intake pipe after the stock airbox had been removed, and before the P-Flo was installed. While not exactly piece-by-piece, it's close enough for government work.
Neuspeed
3300 Corte Malpaso
Camarillo, CA 93012
Order Line:: (800) 423-3623
(Continental U.S. only, except California)
(805) 388-7171
(AL, HI, CA & international residents)
www.neuspeed.com
Neuspeed's 1.8t program as tested consisted of a P-Flo, P-Chip, turbo inlet pipe, intercooler pipe, downpipe and cat-back exhaust.
| 
This Neuspeed all-stainless exhaust uses factory mounting locations and hangers for easy installation.
| 
The stock downpipe on the left is constricted and has extra bends. It must be welded to the catalytic converter by a competent welder
|
The first step is to remove the plug from the MAF sensor. Simply pull up on the tab and slide the plug away from the socket.
| 
The rubber boot attached to the MAF sensor is retained by a large hose clamp such as this car, or a spring-loaded clamp.
| 
With the clamp loose, the boot can be slid away from the MAF sensor.
|
On the side of the airbox, there is a hose clipped on that must be removed. The hose leads to an air pump.
| 
The factory airbox is mounted to the car with a couple screws, one in the front, one in the back.
| 
Next, pull the airbox free.
|
Two screws attach the MAF sensor to the factory airbox.
| 
With the two screws removed, the MAF sensor can be slid from its recess in the airbox.
|  |
The MAF sensor is reused. Simply bolt it to the P-Flo heat shield with the included hardware.
| 
P-Flo uses a separate filter for the air pump intake hose.
| 
The next step is to install the turbo inlet pipe. There is a bracket and hose that needs to be loosened from the driver's side of the block in order to slip the intake pipe free. You'll need an 8mm hex socket.
|
This spring clip fastens the turbo inlet tube onto the intake boot.
| 
Ready to go underside to remove the pipe from the turbo housing.
| 
There is a small vacuum hose attached to the turbo inlet pipe. Simply slide it off with a screwdriver blade.
|
A hex wrench is used to remove the one bolt holding the pipe to the turbo housing.
| 
The turbo inlet pipe can now be pulled free.
| 
It's a bit tight sneaking the new larger-sized inlet pipe in, but not difficult.
|
VW has made some changes to the turbo housings, and you'll have to be specific about which engine you have, and whether you're using a K04 replacement turbo.
| 
Although not necessary, Aaron Neumann puts a zip tie on the vacuum hose for good measure.
| 
Refastening the pipe to the engine block.
|
Reinstalling the air intake system.
| 
The P-Flo drops into the same space used by the factory airbox.
| 
Reuse the two mounting bolts to fasten the P-Flo shield to the engine bay.
|