S1 Rallye Inlet and TB

3rd August 2006, 14:47

if you fit one to a black top vtr are the induction kits different? is it a straight swap or do bits need modifying?

5th August 2006, 01:40

bits will need mdoifying...
first you will need to plumb the ICV pipe and blank off one of the holes in the tb, then you will have to swap the two throttle position wires over as it opens the other way... you will also need a longer throttle cable.

as for the induction kit, the s1 tb sits at an angle so basically you don't need an elbow on your induction pipe

in short:

Drill hole in S1 mani plenum for you ICV pipe to fit into

Extend TB sensor wires

Swap the outer 2 wires on the Throttle Possition Sensor (TPS) (I just made plugs on each wire so i can easily swap them back round if i need to)

Plug in Air Temp sensor

Permanatly close Idle stepper motor (Use some gasket paper and a metal plate to seal the whole thing off)

Seal the hole just before the TB butterfly using JB Auto Weld

Plumb in your Map Sensor

Connect your vacum an breather hoses

Block unused vacume/breather take off's

Fit and connect Rallye throttle cable.

Change throttle cable idle control clips and alter CO2 Pot-me-bob thing to get engine running bob on

5th August 2006, 01:49

I've robbed this off Jim_cliff when he did it on his AX_gti... will be the same for black top....

Alrite guys,

Ok after a hard days labour 2day i finally got the cunt on and working perfect! Im well pleased with it tbh, was well worth the money i paid for it. I nearly managed to cut my finger off with a hacksaw in the process tho haha, blood everywhere

It took me about 4 hours start to finish to get original GTi inlet and TB off and then this on and all set up and wired in. But after patience and effort finally got it going right. Tick over is perfect now, it idles at around 750 - 900 rpm and sounds fuking awesome!!!!!!

Below is some pics of the process of prepping it and putting it on:

S1 Inlet and Throttle Body all preped and ready for fitting

ICV (idle control valve) piping drilled and tapped into plenum

S1 Inlet and Throttle Body, as you can see ive blocked up the stepper motor holes with a little plate and some gasket paper.

The inside of the throttle body, if you look carefully ive blocked up the breather hole on the inside using JB Metal Weld.

The inlet finally on, bloody pipes everywhere as well!

Pipe at left hand side of inlet has been drilled and tapped in, its for the ICV (idle control valve)

Engine bay as whole

S1 Inlet with throttle body attached

Inlet and TB again, diff view

MAP sensor pipe extended and fitted to S1 inlet nipple (clear pipe starting to melt haha, need find better one tbh) TPS wiring extended and two outer wires swapped over to make work with new throttle body, as the S1 throttle body's butterfly opens the opposite was to normal. Also the air temp sensor has been extended as well.

Diff view

Fitted nicely, you can see where ICV pipe has been plumbed in

Everything done! All sensors and vacum hoses connected as well. Throttle cable has been made from some cable lying in the shed. As you can see ive put the induction piping on with my green air filter behind the light (or near) and i also drilled and plugged that other sensor into the induction pipe. How u guys like my home made and modified oil breather filter hehe, it was originally off a mower of some kind but i adapted it to fit hehe.

Close up of my home made and modified oil breather filter

Sorry about the quality of pics guys, ill try and get some better ones when i get chance. Im really pleased with how everything went tbh, didnt really run into any major problems at all, which i was pleased about. It started on the first try and ran fine, all i needed to do was set the idle speed on the throttle body as it was idling well to slow and kept stalling. Now everythings fine though.

I think im the 1st person to have done this on the AX GTi, although i could be wrong, not to sure tbh. Correct me if i am.

I would recommend doing this conversion to any AX GTi owner just for the sound that it makes on full throttle, does sound like baby throttle bodies indeed hehe. Roars like a whore!!! Also i have noticed a little increase in power.

6th August 2006, 22:18

And after you've done all that you still need to get it re-mapped

6th August 2006, 23:19

well yes... but its not essential to run the car until that time

6th August 2006, 23:21

There was one on Ebay but it was running at £300, there may also be one on SSC but you'll need to get you wallet out for that one aswell.

There not cheap.

7th August 2006, 14:23

£300 leave it there you can pick them up £100 thats everything you need ....inlet ,TB ,Throttle cable etc

Ive fitted 5 now and have followed that guide AX_Beefy it is very helpfull .... the first 2 i did that guide wasnt available but i got them running roughly then took them for re-map and then there's no need to drill the Plenunm for ICV as its not used and looks a lot nicer

7th August 2006, 14:27

Thinking about getting one for the turbo .... as it is a metal inlet instead of plastic and the TB is 10mm bigger

7th August 2006, 23:27

I could have picked a polished one up for £70! lol.... this will work so well on a turbo!... do it!... I know Martin fromAXOC was going to put it one on his vtr tub ax but don't know wether he has yet