S3 BT build.

The carbon build up on those intake flaps is horrendous.........surprised there aren't more tuning companies out there that do a delete kit for this engine.....As said before it would be a worthwhile business venture.
 
Brodster said:
The carbon build up on those intake flaps is horrendous.........surprised there aren't more tuning companies out there that do a delete kit for this engine.....As said before it would be a worthwhile business venture.
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You'd have thought so,wouldn't you.

Youy've seen the gunk that accumulates on the valve stems,haven't you....makes the flaps look almost OK by comparison.

I'd used a catch can on mine from the start almost,and the crap still builds up,as the can doesn't get all of the oil vapour,thanks to the cam breather which dumps into the turbo intake piping.
Really clever thinking there from someone.
 
can you open your oil breather(catch can), if so you can add stainless steel scouer type material inside the catch can. this traps more vapour as it passes through, did this on my old cossie as it use to breathe heavy before i rebuilt it,
 
S3 03 said:
can you open your oil breather(catch can), if so you can add stainless steel scouer type material inside the catch can. this traps more vapour as it passes through, did this on my old cossie as it use to breathe heavy before i rebuilt it,
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The problem isn't really the catch can but the fact that the cam cover breather also exits into the intake.
 
can you not put that to your breather? cam cover to breather, breather intake?
i pick my new S3 later today, so i dont know what the intake/breather pipes are like yet?
 
S3 03 said:
can you not put that to your breather? cam cover to breather, breather intake?
i pick my new S3 later today, so i dont know what the intake/breather pipes are like yet?
Click to expand...

I can't see why something couldn't be done for it.....my Cosworths both had crank and cam breather/oil separators,which exited oil back into the crankcase.
 
Hi guy's & thank you'es for your support! My apologies for not coming back sooner as I have been on my holidays!

I'm back now & will answer you'er questions!
 
Hope you had a good one.

Time to get back to the serious work!
 
S3Alex said:
Lovely work.

WIll you be using a custom map or APR's RFD map?

I think what you're doing here is superb!
Click to expand...

Hey Alex hows you bro? Thank you for you'er support and comments!!

I have used a few maps over the last few years & not much out there except for Revo & Unitronic can give you mind blowing files! On this particular build I will be using Unitronic S3++ seeing that Revo has not found a way to push there cars over than 500bhp! I have spoken to Revo team last year and asked if there was a file for GTX3076R and there answer was that I was to over optimistic! Well Unitronic seems to help in this department.
 
Errr mm

Mine runs Revo Stg4 software and turns out 500bhp+

I don't know who you spoke to but they do have a number of cars running this sort of power.

I'm fine though...car is in bits right now having some more power sorted. Lol.
 
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Think I spoke to Carl. Our main discussion was the MAF housing on the ITG & seeing it was impossible to have a flow-through MAF system it was only to give 500bhp. 2.75 inch was not up to the job when looking for 500+! Revo HQ are not very helpful when asked how to achieve these figures.
 
Unitronic said:
Think I spoke to Carl. Our main discussion was the MAF housing on the ITG & seeing it was impossible to have a flow-through MAF system it was only to give 500bhp. 2.75 inch was not up to the job when looking for 500+! Revo HQ are not very helpful when asked how to achieve these figures.
Click to expand...

Well myself and a Romanian mate seem not to have problems.
Lol.
 
why does no one get there cars mapped at motorsport developments, surly a custom/live map would be better for the car,
i might try them after a few mods, as stu knows his onions
 
Unitronic said:
Think I spoke to Carl. Our main discussion was the MAF housing on the ITG & seeing it was impossible to have a flow-through MAF system it was only to give 500bhp. 2.75 inch was not up to the job when looking for 500+! Revo HQ are not very helpful when asked how to achieve these figures.
Click to expand...

Give Revo Kev a call on Monday 01327 301 901 or drop him an email - eurosupport@revotechnik.com
Not sure how long ago you called, Carl is no longer with us.


You also have Faisal at Konzept - 0141 951 4447 more local to yourself who's a VAG specialist.
 
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S3 03 said:
why does no one get there cars mapped at motorsport developments, surly a custom/live map would be better for the car,
i might try them after a few mods, as stu knows his onions
Click to expand...


I think that with high power apps like some of these,you go with those who have the most experience and also its worth saying that all of the mapping on mine has been setup on the RR and live on the road.
 
The maf housing or the maf arent up to the job ?
i know any cars wanting to have giac extreme maps have to have the 3 inch maf housing fitted which are availabe from quite a few places,i know Statller do these because his and another 4 or 5 cars down there have them on.

Agreed with comment above though Stu at MSD do know there stuff as anyone who has a ford will know but i dont know how much they are involved with Vag tuning,my mate is a very good mate of his and Stu,Kenny & Will sorted out about 5/10 crazy cossies belonging to them over the years.
 
phil76 said:
The maf housing or the maf arent up to the job ?
i know any cars wanting to have giac extreme maps have to have the 3 inch maf housing fitted which are availabe from quite a few places,i know Statller do these because his and another 4 or 5 cars down there have them on.

Agreed with comment above though Stu at MSD do know there stuff as anyone who has a ford will know but i dont know how much they are involved with Vag tuning,my mate is a very good mate of his and Stu,Kenny & Will sorted out about 5/10 crazy cossies belonging to them over the years.
Click to expand...

A lot of that is down to flow through a constriction and the onset of turbulence or flow limiting and the actual range over which the MAF reads in a linear manner.

When you move outside those ranges you will get inaccurate readings.
The 3" tube will have a higher flow rate before turbulence occurs but the MAF needs to be calibrated to the larger diameter tube or again readings will be inaccurate.
 
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phil76 said:
Hi Bryan

Lovely work on both the Leon and the S3,this looks like a nice thread to keep an eye on , the Cnc work on the head after the rod insert work looks pretty smart its a shame somebody doesnt manufactuer the inserts to remove the flaps on the head side as i think they would be a good seller for anyone doing work in that area already.

nice to see people going to town on the mods and also creates something interesting for us car loving freaks to read.
Click to expand...


Thanks phil76! It does take time and loads of fine tuning!

I have been searching for companies who can CNC these little flanges! The rods are not the problem & fairly easy to make up but very costly to make the RFD! First of you need a programmer to wright you a program to cut these RFD flanges (Not cheep) then you need to at least place an order of 50 sets! You would be better of just buying them from APR.
 
Unitronic said:
Sorry guys i'm just going to try and answer ever ones questions before I jump in on the conversation.
Click to expand...

Best way Rick

If you have an answer to a problem then it helps everyone looking to do this sort of thing.

I did this a few years ago and a lot of what we did was like being among the first to do so and more difficult because of that.

Other people's input always helps.
 
Revo Steve-W said:
Give Revo Kev a call on Monday 01327 301 901 or drop him an email - eurosupport@revotechnik.com
Not sure how long ago you called, Carl is no longer with us.


You also have Faisal at Konzept - 0141 951 4447 more local to yourself who's a VAG specialist.
Click to expand...

Hi Revo Steve!! I have practically achieved exactly what I was looking for on Revo S2+ but thought it was time to bring in a competitor (Unitronic)! I think its good to have something different seeing Revo's the dominant entity UK based & i'm the only Unitronic dealer UK!
 
Right seeing you guys need to know about the PVC valves on the TFSI engine here something for you guys to think and decide!

First of all we must understand why and how!

Lets start at how!!

The concerns about emissions are getting higher & more demanding & tighter every year & the TFSI engine is no exception! It was designed to accommodate these regulations and that's how the TFSI was born from its previous S3 1.8 engine!

The direct injection was one change to fine control the the fueling & economy so this would give extra performance!

Being direct injection it helped with extra cooling and detonation allowing much higher cylinder pressure to be used! The carbon build up are directly the cause of injectors not being over the valves to keep them nice and clean! When the engine is cold the unburned particles are been recycled back in to the engine! This's the problem! Make short trips & make sure you get up to engine temperature quickly! Most of us would start the engine and run it to temperature all though its where the build up starts.

You better of starting you'er engine and drive it immediately at 2.000 revs to temperature recommendations. You could ad BG44K to you'er fuel ones a year but wont clean the intakes! Higher fuel octane! all these can help to keep it clean but not guaranteed.

WMI could help but not proven, it does help to keep the valves clean.
 
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Another problem is that a catch can only catches some of the crap.

The cam breather still empties into the turbo intake so some vapour still gets in to crud up the intake valves.

The upside is the efficiency of direct injection....I can use a 500bhp engine which will still return 30mpg

My Cosworth would do about 10-15mpg. Lol.
 
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This's where the PVC valves play there role keeping & helping the engine warm to its temperatures quicker. Another carbon enhancer we should totally delete! Will continue!
 
Unitronic said:
This's where the PVC valves play there role keeping & helping the engine warm to its temperatures quicker. Another carbon enhancer we should totally delete! Will continue!
Click to expand...

There are a few PCV delete solutions but I guess everything has its downside in terms of probs fitting and so on.

The catch can system is probably the simplest system currently.
 
Welcome back from hols!

This is an interesting thread.

So, catch cans, you guys here sound pretty knowledgable about the tfsi engine - how worthwhile is it to actually run a catch can? I appreciate from reading the above it seems to do something but it is worthwhile for everyday or heavier tunes only?

I dont mean to invade this thread but it seems a good discussion point to bring up given the topic. I have been trying to find out if the expense actually quantifies a benefit for some time but always get differing views.

If I am invading I will open up the question in a new thread :)
 
The higher the level you tune to the more the likely benefits but even a stock engine has this problem as direct injection means there is no fuel passing the valves and cleaning the stems so oil vapours simply coke them up.
 
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Dean_T said:
Welcome back from hols!

This is an interesting thread.

So, catch cans, you guys here sound pretty knowledgable about the tfsi engine - how worthwhile is it to actually run a catch can? I appreciate from reading the above it seems to do something but it is worthwhile for everyday or heavier tunes only?

I dont mean to invade this thread but it seems a good discussion point to bring up given the topic. I have been trying to find out if the expense actually quantifies a benefit for some time but always get differing views.

If I am invading I will open up the question in a new thread :)
Click to expand...

No problem m8 you are more then welcome to dig in and ask!
 
I'm loving all this. Just wish I had the money, expertise and workshop access you guys have. Proper jealous!

Alex: You said your car's getting a bit of a power increase right now. Are you still planning on being at AmD on the 7th? I'm keen on seeing the beast.
 
T3KT0N1K said:
I'm loving all this. Just wish I had the money, expertise and workshop access you guys have. Proper jealous!

Alex: You said your car's getting a bit of a power increase right now. Are you still planning on being at AmD on the 7th? I'm keen on seeing the beast.
Click to expand...

Depends on how work goes and how far along the car is but if I can,I will.
 
Very nice.

Busy as ever I see!

Hopefully things should start arriving for mine as well soon.
Keep up the good work !
 
S3Alex said:
Very nice.

Busy as ever I see!

Hopefully things should start arriving for mine as well soon.
Keep up the good work !
Click to expand...


Thanks m8! really appreciate you'er input!


Was just wondering about you'er bearing replacements on you'er box? What did you do and what bearings did you replace?
 
Eeek

I hope none of those were yours.

All of the internal bearings on the box were replaced with uprated ones and the synchros and selector forks replaced as well.

The gears were fine and the box was structurally sound but the transfer case was badly worn and had to be worn and had to be replaced.

When mine is being "done" the gearbox and clutch will be out and the box will be drained while the diff is put in so we should have a chance to see if there's any wear.
 
lol. Yes m8, they are both mines! I have blown 2 gearboxes with heavy 1/4 mile launches and through this I have lost the gearbox mount too!


I see, the selector forks are they to be replaced & are they replaced with the OEM selector forks?
 
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