The First of its Kind: Integrated Engineering Releases Highly-Anticipated IE450T MK6 Golf R Turbo Kit
After two long years of development, the team at Integrated Engineering has finally announced the release of their IE450T kit for the MK6 Golf R. With their turbo kit bolted on right out of the box, the sport AWD hatch is transformed into a 450bhp monster, with hardly any noticeable increase in spool time. In fact, 435 ft-lbs of torque are achieved at all four wheels, at a mere 3300rpm!
By now you are probably asking yourself how this is even possible on a 2.0L engine that made nearly half that power from the factory. By employing true twin-scroll technology into the cast turbo manifold and pairing it with a state-of-the-art BorgWarner EFR turbocharger, IE was able to keep spool time at a minimum and bring the fastest-spooling big turbo setup to the market.
“We wanted to offer a kit that would dramatically increase the power output without making the car lose its amazing street-friendly drivability,” mentioned one of the IE engineers. We are told the IE450T leaves the car driving just like it did when it rolled off the production line, yet with the power it should have had from the beginning. Gone are the days of the turbo lag and tricky drivability associated with big turbos!
A closer look at the technology behind the IE450T big turbo kit
Software
Although primarily known for their bulletproof hardware components, IE has been making a name for themselves in the software world as well. The team of engineers at IE completely reverse-engineered the factory ECU, giving them a thorough understanding of how the MED9 mapping works, and offering a basis to begin tuning. By use of their in-house engine and chassis dynos, they are able to carefully squeeze every last drop of power out of the engine with precise ECU calibration. The IE450T kit is no exception to that statement, as it uses specific software that IE developed.
The IE450T software features the proper fueling and timing adjustments to increase the power output to approximately 450bhp without any adjustments needed, just the matching hardware. The software was designed with OEM drivability in mind, keeping the smooth Golf R powerband intact, while greatly increasing the power output.
The included software also uses the IE Pro features of no-lift shift and launch control. As soon as the ECU is flashed, it is updated with these features, making for a truly transformed driving experience.
Software delivery couldn’t be easier, either. Included with each turbo kit is the IE PowerLink device, which allows the end user to flash the ECU in the comfort of his or her driveway. This tool can also be used to flash other files to the ECU, such as the 100 octane version, which will be released shortly after the launch of the kit.
BorgWarner EFR 6758 twin-scroll turbocharger
Featuring a billet compressor wheel and mixed-flow Gamma-Ti turbine wheel, the EFR turbochargers are known to spool quicker than the competition, with impressive transient response. With robust ceramic ball bearings housed in the CHRA and a stainless steel turbine housing, the EFR turbos are made with longevity in mind. Each turbo is modified for proper fitment by use of custom made fixtures and test stations. Wastegate preload is set in-house at IE, ensuring proper boost levels right out of the box.
IE twin-scroll cast stainless exhaust manifold
Bringing true twin-scroll technology to the table, IE includes a cast stainless steel turbo manifold, which is machined with a T4 flange to mate to the EFR turbo. Extra attention was paid to the mount flanges, keeping them as thick as possible to remove any chance of gasket failure. Custom made Monel studs and nuts are used to securely fasten the turbo without losing torque as they are heat cycled.
Cast MAF housing and outlet pipe
For proper and consistent mass air flow readings, a USA cast MAF sensor housing has been designed with a fully machined internal diameter and mount bosses. The cast outlet pipe is also a direct replacement for the factory turbo outlet, and is fully machined for factory mount points. These cast items are finished with a long-life black powdercoat finish.
Oil and coolant lines
The IE450T kit includes oil and coolant plumbing that has been designed for the specific application, with use of mandrel-bent hard lines and heat protection in critical areas. All necessary adapters and flanges are included to make plumbing a simple, plug-and-play task. The complex turbo inlet pipe uses a special adapter for seamless integration with the valve cover breather adapter. No modification of factory lines is needed, as each line replaces each OEM piece entirely.
Downpipe
The included V-band downpipe is made from 3” stainless steel, which is mandrel bent and fabricated to directly fit the MK6 Golf R chassis. It incorporates a stainless steel flex section, which allows the engine movement under normal operation, eliminating chances of cracking. At the bottom of the down pipe, a 3″ V-band is welded on, which directly bolts to the IE midpipe (sold separately).
Silicone couplers
Included are the necessary silicone couplers to plumb the MAF housing and the turbo outlet to the intercooler. These are all made from thick 4-ply, Nylon-reinforced silicone, which is finished in a glossy black color. All needed clamps are included as well, which are designed specifically for use with silicone, keeping them tight without tearing the couplers.
Ancillary components
To make the IE450T kit truly plug-and-play, everything is needed for installation (minus a few supporting modifications). IE includes every last gasket, nut, bolt, clamp, and even a set of pre-gapped Denso Iridium spark plugs.
Development and testing
As the first line of this text mentions, IE spent over two years developing the IE450T kit. While that included the significant work on the MED9 ECU and the mechanical engineering work to develop the hardware components, it also included testing and revising.
Once all of the parts were manufactured and ready to be assembled, IE began on their Dynapack dynamometer to calibrate the OEM ECU to handle the increased airflow from the larger turbo. That portion took some time, but the big power numbers and smooth drivability came relatively easily.
The second step in testing the kit was to run it under daily driving conditions, which IE did for several months. Although this seems like a small detail, it was very critical to make sure that every component was ready to be heat cycled thousands of times. The IE Golf R was daily driven for several months with prototype parts and is still daily driven with all of the production components found in the kit.
The kit still had to offer the longevity that the factory components offered, so IE went even further with their testing. Strictly for the purpose of testing, the car was taken on a 2100 mile round-trip road trip, beginning at their high altitude facility in Salt Lake City, stopping in Las Vegas, with a final destination at sea level in California. This allowed them to refine their tuning at all altitudes and truly put some mileage on the hardware components. In a matter of days, the car was taken through various weather conditions and altitudes, only to roll back into IE headquarters in the same condition it left.
To truly beat the turbo kit up, the IE team took the Golf R to Miller Motorsports Park for track testing, located just outside of Salt Lake City. The car drove into the pits after hours of laps in the hot desert heat, with no changes except for worn tires and a driver that couldn’t wipe the smile off his face. All of the turbo components remained unscathed, even after seeing plenty of heat and abuse. Nothing was broken except for the egos of a few Porsche drivers on the track. The IE450T had passed the test.
The perfect turbo kit for the true enthusiast
The IE450T kit was designed with the enthusiast in mind; the person who wants to increase the power from their car without removing any of the fun from it. It is designed to directly bolt on to the car without any fabrication or frustration, with an estimated install time of 8-12 hours. That’s right, you can completely revolutionize your car in a matter of hours and it is easily done with the step-by-step install guide that IE includes with each turbo kit.
A true power increase
While still remaining within the limits of the factory engine internals on 91 octane, the IE450T kit produces just that- 450bhp. As you can see in the dyno plot below, this kit packs a big punch and does not add on much turbo lag from the factory K04 setup it replaces.
Learn more
Head on over to the product page on Integrated Engineering’s website for more product specifics, requirements, and pricing.
To see what others are saying about this article or
to tell us what you think, check out the comments here...
The post The First of its Kind: Integrated Engineering Releases Highly-Anticipated IE450T MK6 Golf R Turbo Kit appeared first on VWVortex.
from VWVortex http://ift.tt/1CN4Zp4
via IFTTT
Comments
Post a Comment