02 Jetta ALH Darkside FMIC kit installed

cuban11182

Veteran Member
Joined
May 29, 2010
Location
North Carolina
TDI
1984 CJ w/ ALH GTD1756, 260 injectors, and Tekmektronics tune
So I finally had time to install the kit (thank you for not killing us Hurricane Dorian). The parts that are fabricated are done well, with nice welds. I'm not overly thrilled with the clamps they sent, and the one that goes from the turbo to the FMIC was not small enough, so I had to put on the crappy spring clamp. In addition to the FMIC, you will need to purchase a European Crash Bar from them. I paid £ 558 which equates to $675.38 shipped to me here in Miami. The kit didn't come with instructions, so that took time to figure out (hopefully my pictures help someone in the future).
These are the install instructions from the best of my recollection.
1. Take off the old stuff.
2. Take off the bumper, passenger headlight, and factory crash bar.
3. Mount the top pipe (the one with the MAP sensor bung) into the intake with the appropriate silicone tube and the bottom pipe (the only other long one) and route it to the front of the car. You will have to trim your passenger wheel well plastic so that it doesn't bunch up (you'll see it).
4. On the Euro crash bar, look to the passenger side and you'll see a reinforcement bracket that you will have to drill the spot welds (12 of them) and push it out. The smallest pipe that goes from the upper pipe goes THROUGH this hole to mount to the top part of the intercooler.
5. After the pipes are mocked in place, mock up the intercooler with the attached brackets. They mount to the plastic rad support surround where the top bolts for the bumper mount to (the three going vertical). You'll have to drill holes, and mount with the included allen bolts and nuts. The small bolts and washers go into the cooler.
6. Mock up the Euro crash bar and trim the crap out of it so it doesn't come in contact with the cooler. Realize that the plastic rad support is sagging a little as there are 4 T20 (or 30) bolts that support it to the crash bar. You WILL NOT be able to use the factory bar unless you trim out a TON of spot welds and pull the reinforcement piece. This is just my advice. Where there's a will, there's a way, so I'm sure someone has/or will do it.
7. You will need to trim the silicone adapters. The part that goes into the turbo, cut it down about 2 inches so it doesn't rub against the engine. The big "V" that goes from the top pipe to the small pipe (that goes through the crash bar) will be chopped WAY down.
8. Once everything is looking good, tighten down the clamps, taking into consideration the front 4 that go into the cooler and the bumper that will need to go back into place.
9. Put the car back together, and go for a spin.
https://imgur.com/fVegHAL
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https://imgur.com/TURXgQz
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https://imgur.com/70QLalQ

So feels are that it takes a little longer for me to build boost, but I'm not getting as high EGTs as I was before. I'm happy with the upgrade though.
 
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cuban11182

Veteran Member
Joined
May 29, 2010
Location
North Carolina
TDI
1984 CJ w/ ALH GTD1756, 260 injectors, and Tekmektronics tune
Thats a huge IC notice any performance improvements? The lower EGT is nice but more lag is not...
My lag was a boost leak. Car is back to normal now. EGTs are lower, so that's an added benefit. I also bought it with the intention of taking the engine out of this car and putting it into a Jeep or something eventually
 

MAXRPM

Veteran Member
Joined
May 7, 2008
Location
US
TDI
00 Jetta and 99.5 Golf, 2015 Passat TDI,BMW 2
What kind of sidemount did you have before and what kind of IAT are you seeing now with FMIC compared to SMIC i guess FL got the perfect weather for the test, i just finished installing my FMIC, i went with CXracing, i had to pull crash bar out, but i will put it back and trim it to make it fit in there, i had a few 2.5 tubing around and i was able to fit it to my gtd turbo, i haven't tested yet
 

Yourbuddysatin

Veteran Member
Joined
Oct 28, 2016
Location
Pennsylvania
TDI
2013 Jetta tdi
What kind of sidemount did you have before and what kind of IAT are you seeing now with FMIC compared to SMIC i guess FL got the perfect weather for the test, i just finished installing my FMIC, i went with CXracing, i had to pull crash bar out, but i will put it back and trim it to make it fit in there, i had a few 2.5 tubing around and i was able to fit it to my gtd turbo, i haven't tested yet
Get a euro crash bar and no modding needed. Exit tube passes thru the inside of the bar.
 

MAXRPM

Veteran Member
Joined
May 7, 2008
Location
US
TDI
00 Jetta and 99.5 Golf, 2015 Passat TDI,BMW 2
You said $675 for a crash bar that's expensive
 

MAXRPM

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Joined
May 7, 2008
Location
US
TDI
00 Jetta and 99.5 Golf, 2015 Passat TDI,BMW 2
$675 for everything.
Ok im trying to get me the euro crash bar, but on darkside website i cant see it, do you happen to know approx how much it was
 

ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
The instructions are attached to your order?

The clamps are what we run on the Arosa at 60+ PSi so those are fine, they just need to be tight!

Sorry you got the wrong clamp, we can sort that if you need.

Thanks for the writeup!
 

cuban11182

Veteran Member
Joined
May 29, 2010
Location
North Carolina
TDI
1984 CJ w/ ALH GTD1756, 260 injectors, and Tekmektronics tune
Hi Ryanp,

I just looked up my order and the only instructions listed were for the fitting of the intercooler piping and how to trim it. It didn't list which pipe was which, but we were able to figure it out. I need to double-check to make sure they are tight. I was able to use the old clamp, so no worries. I did ask for a quote for a replacement silicone boot from the turbo to the lower intercooler pipe.
 

MAXRPM

Veteran Member
Joined
May 7, 2008
Location
US
TDI
00 Jetta and 99.5 Golf, 2015 Passat TDI,BMW 2
Ryan p pls redirect me for the mk4 jetta euro crash bar on your website i cant find it.
 
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ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
Ryan p pls redirect me for the mk4 jetta euro crash bar on your website i cant find it.
Email Sales and they will tell you how to order with the kit.
 

ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
Hi Ryanp,

I just looked up my order and the only instructions listed were for the fitting of the intercooler piping and how to trim it. It didn't list which pipe was which, but we were able to figure it out. I need to double-check to make sure they are tight. I was able to use the old clamp, so no worries. I did ask for a quote for a replacement silicone boot from the turbo to the lower intercooler pipe.
PM Me the order ID and I'll check why the instructions were not on there. They are very detailed!
 

MAXRPM

Veteran Member
Joined
May 7, 2008
Location
US
TDI
00 Jetta and 99.5 Golf, 2015 Passat TDI,BMW 2
Pls PM me their e mail address
 

MAXRPM

Veteran Member
Joined
May 7, 2008
Location
US
TDI
00 Jetta and 99.5 Golf, 2015 Passat TDI,BMW 2
Get a euro crash bar and no modding needed. Exit tube passes thru the inside of the bar.[/QUOTE

They replied and said they do not supply (sell) euro crash bar if I have a different brand of FMIC, so basically I needed to order their FMIC with the euro crash bar
 
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cuban11182

Veteran Member
Joined
May 29, 2010
Location
North Carolina
TDI
1984 CJ w/ ALH GTD1756, 260 injectors, and Tekmektronics tune
They replied and said they do not supply (sell) euro crash bar if I have a different brand of FMIC, so basically I needed to order their FMIC with the euro crash bar
The crash bar was one that was used (out of a junkyard is my guess) as it came dirty and you can tell it was used. Maybe reach out to junkyards out there and see if they will sell you one.

If not, get a bunch of grinding disks and cut out all the reinforcements on a US one. You can get it to work, but it's going to take a while cutting to get it to work.
 

MAXRPM

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May 7, 2008
Location
US
TDI
00 Jetta and 99.5 Golf, 2015 Passat TDI,BMW 2
The cx racing or whatever plumbs in just like darkside. Darkside can source a used one if you email them and ask.
You would guess that like I did in the past, but after I read their reply, it was very serious and to the point it said no we won't supply euro crash bar if you did not buy our fmic, so point well taken for me.

And on top you could see that Ryan P never gave me sales e mail from his company, it was Cuban that replied with their e mail, so I thank him for that but I was not able to get anywhere anyways
 
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Yourbuddysatin

Veteran Member
Joined
Oct 28, 2016
Location
Pennsylvania
TDI
2013 Jetta tdi
Hmm I see your point, I apologize. Get ahold of fraunz or however his name is spelled. I know he will source used parts from Europe
 

MAXRPM

Veteran Member
Joined
May 7, 2008
Location
US
TDI
00 Jetta and 99.5 Golf, 2015 Passat TDI,BMW 2
Hmm I see your point, I apologize. Get ahold of fraunz or however his name is spelled. I know he will source used parts from Europe
No apologies instead thx you for your inputs, not a bad idea I will get a hold of Frans he is super nice guy, he takes care of business
 

cuban11182

Veteran Member
Joined
May 29, 2010
Location
North Carolina
TDI
1984 CJ w/ ALH GTD1756, 260 injectors, and Tekmektronics tune
So just a quick little update. I'm still loving my FMIC. I finally found my boost leak, and ryanp was right...these clamps need to be TIGHT! Overall I'm very happy with my purchase, and can't suggest it enough. Totally worth it.
 

MAXRPM

Veteran Member
Joined
May 7, 2008
Location
US
TDI
00 Jetta and 99.5 Golf, 2015 Passat TDI,BMW 2
What kind of IAT readings do you have comparing with the outside ambient temp
 
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