Specs as follows:

Model: 2006 Seat Ibiza Mk3/6L Cupra 1.8T

Engine: 1.8T 20VT 4-Cylinder Port Injected (BBU)

Transmission: 5 Speed Manual (02J)

ECU: Bosch ME7.5

Location: THANAS KZN & THANAS CPT (J2 Performance)

Ziyaad got in contact with us through our CPT dealer, J2 Performance, after removing the stock turbo to replace a leaking manifold to turbo gasket and finding that the exhaust housing was cracked. After discussing the options, and wanting to go hybrid, he decided this was the right time to do so, and he purchased a Taiwan tornado, also known as the Turbo Replacements K04s (fancy name for a K03s hybrid). 

After he fitted the new turbo to the car, he went through the unfortunate process of having to immediately strip it off again, as the incorrect manifold had been supplied, causing a substantial exhaust leak. With the old manifold reinstalled and mated to the new turbo, it could finally make its way to Hendrik, our KZN dealer (THANAS KZN), so that we could get a detailed data-log on the car.  It arrived at THANAS KZN with the following modification already complete:

• K04s (K03s Hybrid) - Billet compressor wheel
• 76 mm Downpipe
• THANAS SAI/Combi Valve delete plate
• Deatschwerks DW200 fuel pump
• Finely detailed BANANA paint
• Seat Sport Front Mounted Intercooler (Not a mod, as it's stock, but it's very much like a mod, it's earned its place)
• 3 bar MAP (Manifold Absolute Pressure)* (unknown to him at the time)

*A MAP sensor is actually installed into the manifold, as the name suggested, what the 1.8T is actually equpped with is a PUT sensor, or a Pressure Upstream Throttle sensor, but because it's colloqually known as a MAP sensor we're just going to go with it :)

The logs revealed a host of issues, from running lean, to not boosting at all, wiring issues were revealed, the usual grocery list of woes. It was in an unfortunate state for such a neat and otherwise very well maintained Cupra. We tackled it one issue at a time, starting with the fuelling. The owner complained that the vehicle would switch off/sputter when cornering. The in-tank pump was removed and we found that the upgraded DW fuel pump was hanging by the pump outlet and the basket was completely missing (note: the pump was not installed by the owner, don't blame him), this explained the issue, as there was no surge-tank functionality,  When the car cornered, the fuel washed away from the pickup, and the fuel supply was interrupted. That was just no good at all, we just want people to enjoy their cars.

 An upgraded, open-canister was supplied by J2 Performance, and the DW fuel pump was then correctly installed, retaining full surge functionality, problem solved (one of the problems, at least). The primary O2 (B1S1) was also replaced with an original Bosch unit.

As the owner wanted to upgrade to a hybrid K03s, we opted to upgrade the fuelling further, as well as add an S3 MAF sensor with matching S3 housing. He chose the Bosch 1000cc (980cc) EV14, with matching J2 Performance billet injector collars (link below):

With the working pump, fresh 1000cc injectors, and S3 MAF installed, we got to work building a custom tune for the car, Ziyaad wanted all the beans, so we went straight from Stage 2 to Stage 2X, our high-octane, high torque approach, that the upgraded fuelling allows for. With the following adjustments:

• S3 MAF scaled in
• 980cc Injectors scaled in
• N249/N112/EVAP delete coding (No resistors here, tyvm)
• Fuelling adjustments for E25 (25% E98 Ethanol, 75% Caltex tap water)
• Torque/Load tables adjusted
• Boost PID adjusted
• Exhaust crackles
• Launch Control
• No lift shift (NLS/Flat-foot shifting)

The car was flashed and logged, but we were just not able to get the boost that we wanted, the vehicle left that evening with something ridiculous like 0.6 bar, and still managed to win a race against a G7 Gti on the streets (the streets of the track, of course).  After some investigation, the actuator that came with the new turbo was found to have failed, causing a complete lack of boost. Unacceptable. The stock actuator was replaced with a MAMBA, piston-type actuator, allowing for better boost control and higher tension on the wastegate flapper:

Back at THANAS KZN, we could finally finish up the tune, and make some respectable boost.

However, with Ziyaad's, let's say "rapid" shifting, the gearbox started to take some strain, and with a number of other items in mind, the trip down to J2 Performance in Cape Town was made. Smooth trip down, couple holes in the gearbox casing and an 800 km flatbed ride, nothing worth mentioning really.

On arrival, Jameel (J2 Performance) got to work with the following upgrades/repairs:

• Rebuilt gearbox with diff-bolt kit
• Valeo VR6 Clutch
• OEM ABF flywheel
• Full 63 mm exhaust
• THANAS vesconite shifter bushes
• Mamba turbo actuator
• Cooler to TB boost pipe
• Rear strut brace
• Caliper refurbishment with Bilstein/Ferodo discs and EBC red + OEM pads

Next up some caliper refurbishment:

And much better, finished in Audi Merlin Purple:

With all of the gearbox repairs done, calipers purpled, full exhaust fitted and boost noodles fabricated, we then retuned it down here on E25, after making a few more adjustments to the wastegate/actuator setup with the new mamba gate.

After a number of revisions to the map, we took it the dyno, and at the owner's request, gave it all the sauce, making a substantial:

Power: 229 kW / 308 hp

Torque: 464 Nm

The owner was more than happy, and with that send-off, he embarked back to KZN, after his CPT boost-cation.

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