A4 B7 After remapping problems...

Hi guys!
I just want to share my experience about remapping and ask you some advice. I have an A4 B7, 1.9 Tdi and I recently installed one of the remapping boxes that give you 30hp more (From 115hp to 144ho).
The plus side of the remapping is that it gives me more mpg (60-63mpg on motorway compared to 50-53 before). The lag of the pedal gone and it's really responsive now, a great drive. But....
Started having problems shortly afterwards. I never had engine or drive problems before (had the car for 3 years and done 35k (it has 163k on the clock).

1.) First one was more noise from the engine. After inspecting I realised that the engine cover looked to be loose (two of the rubber things between the cover and the engine were consumed and the plastic vibration Was the problem. I wasn't able to find those online so don't know if it's possible
change them.

2 .) Noise while turning wheel to both sides: after some research, it looked to be a cv boot. Inspected both and looked to be perfectly clean and tidy. Anyways took both half shafts off and after inspection turned out that both inner cv were gone.
Replaced both, installed and the noise While turning disappeared.
I suppose that given the higher torque after remapping the inner cv's just got worn faster.

3.) Now after driving about half a tank it feels like on acceleration there is a micro vibration on the gas pedal. I've noticed that between 1.5 and 2.5 thousands rpm I can feel the vibration. Then it disappears after 3000rpm and doesn't get back when decelerating.
After some research it looks like the flywheel. This could be an expensive one if it turns out that it's the flywheel..

Could someone advise me on the last one?
I want to anticipate that when changing the half shaft inner cv, upper or lower arms were not removed so it can't be an alignment or balancing problem ( I used all torque specification from Audi when reinstalling.

Nothing else comes into my mind beside the flywheel. The vibration is not major, but really only I can feel it as I know that it wasn't there before.

Thanks.

Rick @ Unicorn Motor Dev. said:

If you are going off the display our mpg increase is wrong. The biz fools the ECU into thinking it is using less fuel than it actually is. It's also probably giving you too much torque very low down so the transmission is under too much stress

Rick

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So do you think it can be the flywheel?

desertstorm said:

I think you are getting confused between a remap and a tuning box. There is a world of difference. A lot of tuning boxes for the 1.9 TDI are simply a resistor and some of them are well expensive over £100.
At 163K the DMF and clutch will have seen better days. By increasing the low down torque you may have pushed a borderline failing clutch / DMF over the edge. I would try taking the tuning box off and see how it runs without it, worn CV joints are common if the gators have split and the joint gets water/ grit in it. The CV boots seem to crack very easily.
If you can put a picture / link up of the tuning box that would help. Where does it connect to on the engine ??

Karl.

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Hi Karl, thanks for your reply.
I am attaching the tdi box that I have installed. Paid £124 for it.


Here is the link to the website as well: TDI Tuning - Diesel Tuning Boxes - Diesel Tuning Box - Browse Products[]=0000000316/category_drop_down_1=0000000007/category_drop_down_2=0000000008/category_drop_down_3=0000000079/category_drop_down_4=0000000316/

It connects to the engine sensor of which I don't know the specific name. Here you have a specific picture:


For the cv joints, they were actually perfect when I took them out. Inner and outer had no gators worn or split whatsoever. That was my initial concern as I wasn't able to understand why there was a clicking noise when turning. I looked a lot on the web in order to be able to diagnose the failed inner joint. After changed I have no clicking now.

I will try to remove the the tuning box today and will let you know how it runs without it.

desertstorm said:

Heres what my tuning box looked like.I left it on for a day just to gauge what it would do, I was getting 70mpg on a journey where I would normally get 45 mpg.



You could make an adjustable version with a 150 ohm resistor in series with a 100 ohm potentiometer

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Hi Karl, this is impressive!
I would have never thought its so easy. Plus it looks I was robbed....
On top of that I got all the failings....

Do you think the flywheel is going bad because of the amount of torque I get?
What would you recommend beside removing the Tdi box and reclaiming my money back?
The car looks lively but of the problems will continue coming...turbo..injectors?...