DBilas Dynamic (multi-valve intake system) Throttle body kit

[CupraMarty]

Hi, i dont know if anyone can help me out with this... but here it goes. i have recently sold my Mk3 Golf and opted for a SEAT Ibiza Cupra Sport GTI 8v with the AGG Engine code.

I have been working on the car for around 12 months and is coming on nicely as im tuning and modifying the engine.
I have bought a DBilas Multi-valve intake system which basically replaces the intake manifold and throttle body... all has been going great and Dbilas Dynamic believe that there is a 25-30bhp gain when remapped... one problem that we have with the installation is that the throttle position sensor from the AGG engine is not compatible as the new throttle body is designed for the the 2E engine!... they currently dont make this item for the AGG engine... so it looks like i have more converting to do! 

Does anybody know if there are any other throttle position sensors from any of the other engine codes that use the same connection to the wiring loom as the AGG?
The only differenced i can see is how the sensor fits to the throttle body.

Hope somebody can help me out here as its almost done! 
Many thanks
Marty

[rubjonny]

main problem is the AGG tb also contains a stepper motor to control the idle. if you dont need this anymore then just bin it and fit a 2e or abf throttle body with a bog std 3 pin tps

actually abf tb isnt quite same as 2e/agg, so use a 2e tb

[CupraMarty]

Oh nuts.. forgot about that. Thanks for your advice rubjonny though. Well.. Dbilas have not specified that the stepper motor will be required! Im sure there are ways around that, but we will just have to see how it idles once the multi-valve intake has been installed. I do have a standard 3 pin TPS for the 2E ready to go on if i can simply rewire it. Dbilas did question me if its possible to use the 2E wiring loom... however i think that will mean converting all the sensors which i would rather not do.

Marty

[rubjonny]

how are you managing the engine, i assume its aftermarket since you're talking about remapping and you have a different tps plug? if so it should work the same way as it would on a 2e engine. in those they have an isv for the idle, and since this is in the inlet manifold so would also have been lost when doing this mod i assume you wont have any problems at all?

the other differences between the 2e and agg is the 2e uses an afm and agg has a maf, plus the 2e dizzy is different as well.  so depending on what the management does for both these things you might have to swap 2e items on

[CupraMarty]

The kit is after-market and is bolt on, i agree if there is no isv in the new inlet manifold (there isn't) then this should in theory work without the stepper motor... Just going to have to fit the intake manifold and see how it runs, i'll hook the VAGCOM upto it when installed too.

I have had to replace the injectors for the 2E ones, including the rail. As the remap comes as part of the parcel id imagine that the ECU will be set up for that change.
If i have problems then i'll have to look at converting either an ISV or stepper motor to work with the new intake manifold... this is my own fault for not looking into the kit properly, good job i have a donor agg engine in the back!

Ok cool, dont think there will be any problem with the dizzy or the MAF, but if they will need swapping then we will swap them. The TPS should work in the same way, but the fitting screws on the sensor are just on the one side on the agg and the 2e has a screw either side, so may have to bastardise that to work too, just as long as its neat and it works!

[rubjonny]

if the setup uses the 2e ecu, then uyou'll have a lot more work to do as the ecu is different on the agg

plus you will need to change the dizzy as the 2e one uses a 4 window trigger wheel, and the AGG one uses a single window trigger wheel. the AGG gets a crank sensor signal too, which the 2e doesnt even have!  worst case i think you'll have to change the whole engine loom and ecu for a 2e

[CupraMarty]

Hmm.. well the ECU they have is from the spare AGG engine that i have.. so i will have one standard ECU and one remapped both AGG.
Oh ok, didnt know that, thanks for the info mate! 
you have just reminded me i need to replace the crank sensor. Well... if it comes to that then yeah i'll rerplace the wiring loom with the 2E... either way the project is not getting scrapped! 
Just isnt so straight forward lol

[rubjonny]

ok that makes things even more fun

so whats happened to the old stepper motor/tps plug, was it chopped off and repalced with a 3 pin one?

[CupraMarty]

I'm based in Aldershot at the moment so don't get to go home and work the car until i get back, only have 3 days off every 9 days so that doesn't give me much time to get on with it, however there are 4 of us working on it so it makes all the difference! One of whom is a VAG breaker and his ramp comes in useful!

The old stepper is still on the old throttle body... may have to try and incorporate it but we will have to wait and see! As for the TPS i am going to try and use the AGG one if i can make a good enough fitment for the new throttle body which is built into the intake manifold... i will show you a link of the intake manifold so you can get an idea of what it is if you have not seen one before. But yeah the other option is to use the 3 pin plug... i just have to find out what wires go to which wires lol and connect it correctly. im not in work until 2 till 10 tonight so at least i get chance to plan it in the day for when i get back.

http://www.dbilas-shop.com/Products/Throttle-body-kit/Street/VAG/Throttle-body-kit-for-VAG::244.html

after reading this i think i will need the isv... hmm this is new, i bought this before it was advertised for the 2E engine and this was through regal-autosport.. there wasn't a lot of information on it when i bought it. However i'll get it sorted!

the modifications so far are:

Custom longlife stainless steel exhaust cat back system including a hight flow sports cat.
4 branch stainless echaust manifold.
DBilas flowmaster system.
FK Street coil overs.
yellow stuff break pads.

To be done/in process:

Multi-valve throttle body.
ECU Remap.
Cams at some point.
Rodel Mulitispoke white alloys. 15's or 16's.

[rubjonny]

looking at pic number 3, theres a long loop of vac line with a T piece in the middle, i bet this is where the ISV is supposed to go. trouble is the agg ecu has no isv control, so i cant see how it could be made to idle nicely, you will only have the basic tb angle adjustment?

what you might be able to do is utilise a kr isv controller, or even a mk1 AAV. the kr controller only needs an ign live and a rev counter feed (which you will need to take from the -ve terminal found inside the MK3 coil) the aav just needs a fuel pump live signal