After the engine replacement, the Polo had a knocking problem from the right side – especially during slow driving on bumpy roads. As it turned out, the culprit was the turbo pipe.
Unfortunately, as it turned out, the much cheaper pipe from Golf 6 / Audi A3 (1K0145762BM) for the 2.0 TSI CDL EA113 has the wrong shape – it’s too long and was hitting the Polo’s chassis rails:
The pressure pipe from Polo WRC Street is much shorter and requires an additional turbo outlet that cannot be purchased separately. Fortunately, there’s a better option available – a pipe from HG Motorsport, which also increases airflow – an ideal solution, especially since the Polo was lacking air on warmer days. In the Polo 6R/6C, Audi A1, and Seat Ibiza chassis with 2.0, instead of 1K0145762BM, you should always use 6R0145762AD, because there isn’t enough clearance here.
Correct pressure pipe for Polo 2.0 TSI
A new pressure pipe for Polo costs 3170 PLN from VW and has no aftermarket alternatives (not available in Poland, as it was only fitted to WRC Street and Audi A1 Quattro).
Unfortunately, VAG parts that weren’t used in mass production are usually quite expensive – but after all, if someone wants a cheaper car to maintain, they choose a Golf, not a Polo…
Fortunately, I managed to order it from some Dutch website:
Part number: 6R0145762AD
Price: 99 EUR + 20 EUR (shipping)
The package arrived quickly and without problems:
HG Motorsport turbo outlet
The turbo outlet from HG/HF-Series improves airflow which directly affects turbocharger response. The aluminum outlet fits Plug&Play to Polo with factory K04-64 turbo from BorgWarner.
Part number: HGPPVAGTOK4WRC
Price: 189 EUR + 9.20 EUR (shipping)
Unboxing
OEM vs HF-Series outlet comparison
The improved outlet eliminates unnecessary bends, which improves airflow – this is nicely shown in the animation from HG Motorsport’s website:
Several shots comparing it to the factory outlet and the installation process can be seen in this video from @BertRacing:
Comprehensive intake system modernization
Replacing the pressure pipe and turbo outlet is part of a broader intake system modernization in the Polo 6R 2.0 TSI. Previously, a Wagner Competition intercooler (200001061) with TUBE&FIN core was already installed (replacing the factory intercooler is particularly important due to its tendency to overheat under higher loads).
The next step will be replacing the air pipe leading from the air filter to the intake manifold with turbocharger (OE: 06F129654). The factory pipe will be replaced with a larger diameter pipe, most likely made of titanium.
All these modifications aim to improve airflow through the entire intake system – from the filter, through the turbocharger, intercooler, to the intake manifold. This allows the EA113 engine to operate under optimal temperature conditions and achieve better torque characteristics.
I’ll write about the next stages of modernization after completing the work and road testing.
