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Unitronic turbo inlet


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#1
T-800

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Finally got around to fitting the Unitronic turbo inlet elbow.
Thanks to Simon Sharp @TTE For the Elbow.

Fairly straight forward install......

Unitronic official instructions say it can all be done from the top, unlike I.E and Forge which require the lower cast pipe to be removed to access the inner elbow bolt.

I opted to do it all from the top.


First up remove the engine cover to expose the coil packs etc.
Then remove your intake pipe
56c42f29eb27d230ec47895b1cf2e3c1.jpg
Undo the coil pack connections to number 1 & 2
941014cdd11a1fc506e04b6498deb0a6.jpg
Then unclip the cam solenoids on 1 & 2 by pulling back on the red lock tabs then pressing down the black tab.
12a2195b43b027fd4ded97d85c57acb1.jpg

Undo the cam sensor

7ac771fbb1f651444e1b4114e3b23e1f.jpg

Undo the 3 nuts and move the coil wiring bar out of the way.
84939e225c802af8d3d2adcc3b71f69a.jpg
Then remove coil packs 1&2
09559e4a6016b2a30dfc9471d6c313b2.jpg
Next turn your attention to the boost vacuum line.
Undo the support bracket on the side of the oem elbow, a Torx 30 bolt
5390414c902cacdfa702e2f5b44ef45a.jpg
Pull the vacuum line off the actuator and at the point near number 2 coil pack where it connects to the silicone line.
3775e5d93c777ed964861c519b6baec5.jpg

Next undo the Actuator off it’s mounting point and pivot arm, 2 x 10 mm nuts and a circlip on the wastegate arm
e73d70d6df9d678b970148e049476090.jpg
5d061abee0197569c4dc768f38ac68f2.jpg
Then let the actuator go through the mounting hole so it’s out of your way
https://uploads.tapa...7f321ef21fd.jpg


Next you’ll need to undo the 2 off Torx bolts that hold the oem elbow in place.
The inside one is a tricky one to remove but with patience it can be done, you’ve just got to get a ‘feel’ for where it exactly is and how to get the ratchet/Torx bit onto it, I found 2 hands for locating the bit easier, once you are in the bolt head it’s just a matter of loosening it enough to remove it by hand, carefully so you don’t drop it.
Once you have removed it then you can undo the easier outer one that you can actually see.

I’ve arrowed the one you can’t see, it’s directly opposite the circled top one.
https://uploads.tapa...06b7f9538d7.jpg

Once you’ve undone those 2 Torx bolts then you need to undo the breather pipe from the engine PCV system.
3 Torx screws to be removed here
https://uploads.tapa...9b1a9a7c81c.jpg

Now you can withdraw the old elbow
https://uploads.tapa...f99243f8284.jpg
Next you’ll need to remove the breather pipe from the old elbow.
It’s locked into place with a security fastener
https://uploads.tapa...9c9d1f835ae.jpg
Use a Dremel with a grinding disc to cut a groove into the head and remove with a flat blade screwdriver.

Once the bolt is removed pull out the breather pipe and insert into the unitronic pipe, using the Allen bolt supplied to secure.
https://uploads.tapa...5e7e2213692.jpg

Transfer the flange seal ring from the old pipe to the Unitronic pipe.
https://uploads.tapa...32d3c3692f2.jpg

A shot here of the area you are putting the new elbow into.
https://uploads.tapa...956a62bda5a.jpg
The above gives you an idea of exactly where that inner Torx bolt needs to go.

Take the Unitronic elbow and insert carefully into the turbo opening, keeping an eye on the seal (don’t let it fall off).
Once it’s in place you can insert a Torx bolt to hold it in place, just do it up by hand for now, next insert the rear Torx bolt, I started mine by hand carefully and screwed it in as far as I could by hand before finishing with the ratchet.
Then tighten the one you can see, ensuring the flanges are seating together squarely.
https://uploads.tapa...aae36174fb9.jpg
Refit the actuator and reconnect the wastegate rod with the clip.

Refit the actuator vacuum line, I connected it to the actuator 1st and to the connection near the coil 2nd ensuring it was seated correctly around the new elbow then tightened up the bracket bolt.

Reconnect the breather pipe to the PCV system making sure the pipe sits in its place at the back under coils 1&2
https://uploads.tapa...81338377471.jpg
Once done it’s just a matter of inserting the coil packs you removed earlier, bolting them down, refitting the coil wiring bar bolting that down, then reconnect the coils/Cam solenoids/cam sensor.
You’ll then have your new elbow ready to put your hard pipe back into.
https://uploads.tapa...6ea40b0fa23.jpg
Hard pipe fitted.
https://uploads.tapa...ba4efd7cbed.jpg


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#2
toosmiles

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Great write up

is this the 3"?


533bhp Mk6 Golf R 


#3
T-800

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Great write up
is this the 3"?

it is yes.
4” will not fit because of the brake servo.


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#4
T-800

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To anyone thinking of ordering this..... don’t !
It’s not suitable for RHD cars.

Under hard acceleration it makes contact with the brake servo.

You feel the vibration through the pedal.

I’ve been advised to remove it ASAP.


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#5
T-800

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Have ordered the Forge version online from Awesome GTI.

I must say they weren’t too accommodating when I wanted to pay over the phone and collect today (too many scams and social distancing they cited) I even offered to pay for Saturday delivery and they flat out said no.


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#6
T-800

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Further update.

It would seem Unitronic shipped some elbows out that aren’t suitable for the RHD cars.

New elbow coming tomorrow that is a revised part.


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#7
RS3Dell

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Further update.
It would seem Unitronic shipped some elbows out that aren’t suitable for the RHD cars.
New elbow coming tomorrow that is a revised part.
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Obviously can't tell there left from there right on the other side of the pond 🥴

Dell.
RS3 8P 2012 Phantom Black, Bucket Seats,Optic Black Pack, MRC Stage 2,+ DSG Remap, Forge Intercooler, Autotech HPFP, HG Motorsport Intake Pipe, BMC Airfilter,Powerflex Gearbox & Dog Bone Mount Inserts, Fully Decatted OEM Exhaust, 443Ps 777Nm,8v 8 Pot Calipers,Reyland 2 piece Discs & DS2500s All Round,Bilstein B14, 034 ARB.MPS4s,VCDs User.

#8
T-800

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Bloody Tapacrap.

Edited by T-800, 23 May 2020 - 07:42 PM.


#9
Evil Diesel

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None of the pics uploaded Sean.



#10
T-800

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Update.

Replacement Elbow came today.

Spot the difference.

IMG_9349.jpg




You can see here the elongated holes that allow you to fine tune the fitting.
IMG_9350.jpg


Much better clearance now


IMG_9351.jpg



Here’s a tip.
Fit the elbow but don’t tighten the Torx bolts fully, fit your coupler and adjust to suit, this is a picture with my coupler fitted before I had to move it forwards, you can see the slight ‘flat’ in the circumference, this is where the coupler is touching the Cam solenoid connector, move the elbow slightly forward then tighten up the bolt you can see on the elbow.
You can then remove the coupler and tighten up the hard to get to Torx bolt.

IMG_9352.jpg

After road testing I can say everything is now fine, there is no servo and elbow contact under hard acceleration.


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#11
Evil Diesel

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Great write up mate.



#12
Evil Diesel

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I suppose the next Q is whether it makes a difference?



#13
T-800

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I suppose the next Q is whether it makes a difference?


Noticeable difference with low down pick up.

Less restriction equals better flow into the Turbo.


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#14
T-800

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Quick video clip showing the range of adjustment you have.

https://youtu.be/XkPCP7FqVg8


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