As you may have seen I've spent some time the past couple days installing the relatively new tCarbon FMIC kit for the 180 motor. Here's a little write-up on how the install went. Click on any image for a larger version.

Here's what was in the box. This kit uses the crossover pipe present (but not used on 180s) to route the charge air. Due to minor shipping damage I was missing some mounting hardware (nuts/bolts).


After consulting with Tylor I was able to procure the correct missing hardware locally. Note the 42DD MAP sensor mount and alien feed line plug in the baggies. The short 1" hose with the plug and 2 clamps is to plug the charge line for the DV relo


1st thing is to take the front bumper cover off. There are several writups on how to do that but I liked this one here due to it being a little more concise.

After the bumper cover is off remove the passenger headlight assembly (3 torx screw) then the inlet hose from the SMIC to the throttle body and unmount the MAP sensor from the SMIC


Next remove the SMIC and associated plastic air ducting. Undo the clamps to the pancake pipe and joiner hose.


There are 3 10mm bolts holding the SMIC on, 2 top 1 bottom, access them from the front. Save these (I needed to reuse 2).


Next install the 2 Z-brackets from the kit by removing the upper inside bumper support bolts and mounting as shown. You can remove the bumper before you do the Z-brackets but I didn't.

driver side


passenger side


If you haven't yet, remove the bumper by undoing the long bolts on each side.

Install the IC tank top support bracket to the Z-brackets as shown. I used 1 bolt, 2 washers (f/r) and a nylock nut on each side. Note which bracket goes where. The top bracket is the one without the tabs on the end.


The bottom support bracket attaches to the radiator housing at the bottom corners. On mine the mounting holes were present but no bolts so I reused 2 of the SMIC mounting bolts. Note again the bottom bracket should have 'tabs' on each end. If things don't seem to be lining up try swaping the brackets (top/bottom). Mine fit perfectly.


When you're finished with those 3 steps it should look something like this:


Next install the tank using 6 sets of bolts/washers


On mine there was a gap on the top and bottom between the IC tank mounts and the brackets. I used a washer to fill them in.


Before attaching any of the silicone tubing I used a Shop Vac in reverse to blow out my metal cross pipe. A bunch of dust/dirt came out so I'd highly recommend it!

Then the elbow piece can be attached between the pancake pipe and cross pipe. It will be obvious which way the tube goes on. If it doesn't seem to fit turn it around.


Make sure the ends are on and get under the car to tighten the T-bolt clamp to the cross pipe. You'll have to remove the plastic belly pan if you haven't already.


Next connect the 'U' shaped tube between the driver side of the cross pipe and IC tank end. The long end of the tube goes on the cross pipe.


Again make sure the tube is securely on the pipe. I had to do a little work to get it over the cross pipe enough.


Now attach the long piece to the outlet of the tank and feed it up toward the intake. At this point I just test fit the final inlet tube to the throttle body.


After much test fitting I came to the conclusion that this was the best arrangement for the coupling and T-bolt clamps. Remember everything must be oriented so as not to interfere with the headlight.


I used a little teflon tape to seal around the MAP sensor screws


Tighten everything down


DV relo hookup


Other end


Note that I did not use the supplied charge port plug. I removed the metal plug from the supplied assembly and used it to plug the OEM line. That way it's easy to switch back if I need to.


I had a hard time finding a good spot for the horns. For now they're here in the driver side SMIC location


Capped alien feed


The coolant tank cover needs trimming


New toothy grin


I plan to post my performance impressions later. For now I am re-calibrating the Boost Machine but at this point haven't noticed any turbo lag alluded to in another thread.

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2000 TTC 180 FT Lake Silver/Gray Unspoiled
APR Chip | Samco TIP | Modshack Stage 3 | tCarbon FMIC | Forge 007P | EvoShield | Poly Dogbone | Borla Catback | Original MKI Arms w/ Poly Bushings | Bilstein/Eibach | Neuspeed 28mm RSB | Stoptech Rotors | OZ ULs 18x8 | H&R Spacers (10f/20r) | Tint (28f/16r)

2005 Touareg V6 Offroad Gray/Anthracite
Revo Flash | Euroswitch | XM | Llumar AT35 Tint | Splash Guards

1998 Passat 1.8T Tip Fjord Blue/Gray
APR Chip | TT DV | Eibach Prokit | 16" Swings | Euroswitch | XM | Tint

Had:
2003 A4 Avant 1.8TQMS APR Stage 1+

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