Talk Morgan Forums Thread Like Summary - Plus 4 GDI Aero Racing Manifold & Exhaust Upgrade

This upgrade has been in planning for a while. My GDI is now three years old, and my only "complaint" has been the super sensitive throttle. I had the opportunity for an ECU flash over in the first six months, but after discussion, left it alone. I've never felt the "flat spot" around 3,000 rpm, but I've had low mpg and a very black exhaust from day 1.

Having said that, it passed the MOT recently on emissions with no problem.

A couple of weeks ago I picked up the full Aero Racing system from the factory, and over the last three days have fitted it and the car is running. I plan to take it out on the road tomorrow, and all being well, I'll take it back to the factory for the Club-sport ECU flash, which brings the power up to around 180bhp.

An owner who has done this conversion e-mailed me with his story, and I also spoke to the Cainmeister as to what to expect. Both were spot on. The GDI manifold won't simply lift out, and the new manifold requires a few mm removing from the inner wing valance for clearance.

I did suffer further complications, especially with my front offside mudflap, which needed significant modification to clear the twin pipes which come through the inner wing valence, then turn 90 degrees just behind the mudflap. In addition I had made a heat shield for the GDI exhaust, which no longer fits, and so I had to make up a new one.

I've taken a lot of photographs, and will post the story as soon as I can, hopefully after tomorrow's road test. The engine already feels more eager, so I'm looking forward to seeing how it performs!

Well, it's done - AR Clubsport full upgrade, done at the factory just two weeks ago. I can only confirm what DaveW has already stated: the upgrade is transformative, the nasty revving on start is gone, engine is much more responsive, yet the hair trigger sensitive throttle is no more. The car is more fun to drive than ever - I know it is expensive, but if you want cheap you should go for Dacia anyways.

Glad you got it sorted and you're happy

However, playing Devil's Advocate you could argue this Clubsport tune (now they've sorted it) is simply what amounts to a very expensive exhaust system. The ECU calibration is just a file that uploads in less than a minute, how much value you put on an ECU calibration is subjective, but I would argue it’s a bit cheeky of Morgan to charge for this one as its clearly rectifying a poor early GDI ECU calibration that by all accounts gives a nasty revving condition on start and a hair trigger sensitive throttle.

If we remove the expensive exhaust from the equation, it seems Morgan are cleverly using the Clubsport package as a way of getting their customers to pay for a necessary software update that should be provide free of charge to resolve the issues that came with a poor early calibration. Surely this element should be a dealer update provided FOC when you take the car in for a service, well that’s how all other car manufacturers operate….. including Dacia

I look forward to seeing it in it's glory soon. Will bring ear defenders

After much deliberation, the Plus4 Club Sport upgrade was selected as the option to go for. Cain at Wolf Performance, with his vast GDI experience, was entrusted to undertake the required work.

At my request the Librands EXA041 silencer was retained, together with a side exit tailpipe. A short 40 degree stainless tailpipe was welded to the silencer. A bespoke stainless bracket arrangement was fabricated and welded to the tailpipe. The bracket was suspended from the existing rubber mounts and eliminated the ungainly stock U-bolt assembly.

MMC had no existing stock of CATs for this conversion and subsequently manufactured a couple to Cain's pattern.

While not having as yet partaken of a dyno session, I have been delighted with the result. From the off, there is noticeably more urgency from the engine and overtaking acceleration is much improved. The burble on the overrun is now perhaps a little more pronounced and accompanied by an occasional chorus of barks. One of my concerns had been the possibility of rev hang being introduced, but there is absolutely no trace of this. My Plus4 had never suffered from a hair trigger throttle and this has not changed.

The cost of this upgrade including labour, new spark plugs and various other refinements was just over £3.5k. As regards "Grin factor per pound", I think that's a good investment.

Very happy bunny


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