Thanks to the good folks at VWoA, et is lucky enough to have a 2006 GLI as a long-term project vehicle. As you've read in past issues, we like the Mk5 GTI's booted brother, but if you're thinking we intend to leave well enough alone then you've not been paying attention. Despite instructions from VW to leave the car alone, we made a few calls in search of added performance and you can read about the results over the next few months.
The 2.0T is the new kid on the block but there's already a good selection of performance goodies to choose from. Over the coming months we'll be looking at several different combinations of software, exhaust and intake for this engine to give you an idea of what works as a first step.
This month we start the ball rolling with reviews of GIAC software, Techtonics Tuning 2.5" turbo-back exhaust, Evolution Motorsports cold air intake and VF-Engineering engine mounts, all fitted to our own GLI.
To gather data we used the Dynojet 224X LC dynomometer in VF-Engineering's Anaheim, CA facility. Testing was performed over a two day period, with almost identical atmospheric conditions. We ran a baseline test of the stock GLI, then uploaded the software, fitted the exhaust and finally the intake.
Our friend Jeff Moss at Torque Factory in Venice, CA carried out all the work. He helped gather many of the parts, installed them and even took the photos. So we owe him a big vote of thanks.
Chip
You gotta love modern turbo engines. Upgrade some software, crank up the boost, and big power gains surely follow. The 2.0T is technologically different from its 1.8T predecessor. Besides being about 200cc larger, the 2.0T also benefits from VW's direct injection fuel delivery. The engine also possesses a high compression ratio more common in normally aspirated engines. So the 2.0T presents several challenges to chip tuners. Despite this, several have already cracked the code and nice gains are being reported.
As mentioned, we chose GIAC's latest program for our project GLI. It increases boost from about 0.8bar to approximately 1.4bar, along with necessary fuel and timing adjustments.
All programming is performed via the OBD2 port, so customers only need visit one of GIAC's dealers to get upgrades.
Exhaust
Like all turbos, VW's 2.0T appreciates a free-flowing exhaust, so we chose a Techtonics Tuning (TT) 2.5" turbo-back system. It's a similar diameter to the OE system but our research showed that some companies are posting better results with a 2.5" system than a bigger 3" version. So we decided to see if we could do the same.
The TT exhaust features a downpipe with a single free-flow catalytic converter. It replaces the two stock cats, and while the emissions are unaffected when the single cat is warm, it's not so good on cold starts because the "warm up" cat nearest the turbo has been removed to improve flow. So a smog test is best conducted with a warm engine, rather than a cold one or one that's been idling for an hour.
The 2.5" TT exhaust system has less restrictive Borla mufflers, mandrel-bent stainless steel tubing and polished dual tips. The tips aren't anything special but in California where they disapprove of everything, we're happy to slip past cop cars unnoticed.
Sadly, we don't have any installation photos for the Techtonics exhaust because of certain technical difficulties encountered by our photographer (Jeff swears somebody messed with his camera!). However, it's a pretty simple process. You'll find it helps to have a reciprocating saw handy when it's time to remove the stock system, and we'd advise caution when removing the portion connected to the turbo - although our GLI is brand new we still managed to strip the thread off one of the studs into the turbo outlet (where the downpipe attaches to the turbo). It took hours with a die to re-cut the thread. This is a fairly common problem on turbo cars with the heat involved and the design of the studs, so take care.
Installing the TT system is simple if you have access to a lift. All the hardware is supplied and you simply clamp it together, hang it from the rubbers and tighten it once you're satisfied it's correctly aligned and you've allowed sufficient clearance front to rear.