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My minor modding thread

Discussion in 'A3/S3 Forum (8L Chassis)' started by <tuffty/>, Jul 29, 2009.

  1. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 15, 2012]
    Quantum Platinum 5w40 fully synth :)

    <tuffty/>
  2. superkarl
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    superkarl MAN OF STEEL

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    [Jan 15, 2012]
    Running in oil I mean? :)

    That's what i have my car on normally, am i running on running in oil?! Haha
  3. Lee172
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    Lee172 GT3071

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    [Jan 15, 2012]
    Im sure your aware tuffty , i bodged the hell out of my engine earths. I think i will move it up on my todo list. ;-)
  4. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 15, 2012]
    Ah... that'll teach me to skim read... currently 10w40 semi synth although mineral oil is normally what gets used... all I had to hand and does the job tbh...

    <tuffty/>
  5. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 15, 2012]
    lol... get it done :)

    <tuffty/>
  6. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Jan 15, 2012]
    I ran mine in on 15w40 mineral oil from Wilkos.

    Changed at 30miles, 200miles, 500miles then went over to synthetic around 800miles.
  7. Buzzer
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    Buzzer Member

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    [Jan 15, 2012]
    Tuffty, my wife hates you!
    Iv been reading this post for ages tonight and she had to do all the cooking , cleaning, and putting the kids to bed, getting uniforms sorted etc
    So, Tuffty , at least I love you.(cant stand those chores)
    Great read and bless you patience.
  8. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Jan 16, 2012]
    Some real man love there :friends::kiss:
  9. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 16, 2012]
    LOL... you guys....

    <tuffty/>
  10. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Feb 11, 2012]
    Minor update... had the front tracking checked this morning as I noticed my low mileage front tyres had worn badly on the outside edge... was toeing in a bit so thats now sorted...

    Grabbed a bit of time during lunch to fit my TFSI coil packs... (07K 905 715 F)

    They are longer than 20v coils with a slightly thicker top too...
    [​IMG]

    I re-gapped the plugs to 0.85mm... 0.5mm more than std and 0.15mm more than the 0.7mm I normally do for remapped engines... everywhere I read suggest using a gap of 1mm... I haven't for a couple of reasons... 1).. I wasn't running the car on the dyno to see what worked and what didn't and 2)... I need to put the std packs back in for when I take the car over to get them changed under the recent recall... so I played it safe until I have got my new packs and get the car back on the dyno...

    Anyhoo... you can see the difference in height between the TFSI and 20v coils here...
    [​IMG]

    ...and all fitted...
    [​IMG]

    Now I know the more eagle eyed ones of you will have noticed I am not using adaptors... a couple of reasons for this... they aren't ready yet... and I noticed when fitting mine that the coil leans over towards the back of the engine...
    [​IMG]

    Not sure why but they all do it... it may be because of the position of the cam cover... i.e. there could be some movement on the studs and I have it too far forward or something... I don't know but they are in pretty solid... not having seen a set of adaptors from A N Other manufacturer in the flesh then I don't know how loose a fit they are as you can see clearly that the rubber seal is in the cam cover hole so is holding the coil in but the little tangs either side (20v coils have a single one) are proud of the hole so the coil 'could' rotate... what this is like on the other variations of TFSI coil pack I don't know but I think I will see what can be done to counter this issue with the adaptors Bill is looking into..

    So... seeing as I haven't run the car on the dyno I can't give any info on any power improvements (if there are indeed any to be had) but I can say that the engine certainly feels smoother on idle and part throttle feel is improved... I have also done a couple of stabs at full throttle and no misfires...

    I would say that this and the earth mods I have done have certainly improved the feel of the engine on idle and general drivability under no load conditions... how much of an affect it has had in terms of power I don't know... I will of course try and sort some comparisons out when I get a chance but I still have some tweaks to do to the mapping (as neither of us have had time to do anything more with it) and I still have a coolant leak to find/fix...

    This mod is also supposed to improve fuel economy too... will see how that goes but not promising anything LOL!!....

    One last update... after the agro I have had with some prize tw@t on eBay over the AEB manifold I bought before Christmas I ended up buying another from eBay and it arrived this week... w00t!
    [​IMG]

    ...so at some point I will be looking at making an inlet manifold...

    Next on the cards will be relocating the battery to the boot, fitting the WMI (finally) and reworking the charge pipes as I am not happy with them currently... not sure exactly what I am going to do but once the battery is out the way I will decide then...

    I also plan to replace the coil pack wiring loom too... this can be bought quite cheaply and seeing as most of my plugs are broken and I 'repaired' the cracked loom a couple of years ago it makes sense to do...

    <tuffty/>
    Last edited: Feb 11, 2012
  11. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Feb 11, 2012]
    Very interesting stuff mate. I've got 4 TFSI coils in the garage waititng for adapters but I might try them without like you have.

    I'll be keeping an eye on your battery relocation when you get round to it. Oh and your inlet mani as I have an AEB mani sitting in the garage too :)
  12. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Feb 11, 2012]
    Why are you after a push down cam cover when you already have one mate? yours is a BAM isn't it?

    I think I would prefer to use adapters in the long term as I think it will hold them nice and securely...

    <tuffty/>
  13. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Feb 11, 2012]
    I'm after one to paint up in prep for my engine build so that I don't have to waste time re painting the one currently on my BAM head.
  14. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Feb 11, 2012]
    Plan++ :)

    <tuffty/>
  15. Gops
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    Gops 6th gear @7000rpm

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    [Feb 11, 2012]
    Looks good mate!! Im looking for a BAM cover so i can get these coils. I was looking on the tfsi coil thread and some people on another forum did say the 07k tfsi coils wernt as good as the 06E ones..? Cant seem to find a BAM cover anywhere!

    But great info here, really helps people like me who want to do this but had second thoughts just incase I mess it up!
  16. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Feb 12, 2012]
    I have set my plug gap at 1mm and its runs fine
  17. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Feb 12, 2012]
    what boost/power are you running currently Andrew?
    relative to the gaps you are running... being my question.

    more load.. higher cyl pressure.. better judgement.

    running them on mine also.. so i will see shortly
  18. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [Feb 12, 2012]
    On base map with N75 unplugged, boost at about 12 ish psi, power less than 300 bhp right now
  19. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Feb 12, 2012]
    Not gonna tax the gap at that tbh... std TFSI gap is 0.85/0.9mm IIRC...

    Bill has been playing with my map today and tweaked the boost delivery and peak boost... I have my winters on at the moment so couldn't be bothered to swap them over plus Bill was running in the Ibiza and we did some interesting testing this afternoon...

    I ran the car up the road and once warm put the boot in while in third... needle swung to just over 2bar and I had to look down to check I wasn't in second gear lol...

    On the 20v coils when I was having boost control issues, anywhere close to 2bar would bring on misfires all over the place... the TFSI's held solid... this was nice to know but obviously the 2bar wasn't... even managed to break traction on the winters in third which was a little shock :)

    Boost has been turned down now and all is good... not checked properly yet on the way back from the unit but I haven't seen 2 bar again and on the odd occasion I glanced over the boost gauge was sat around 1.6 bar and still pulling like a train... and wheelspinning everywhere...


    <tuffty/>
  20. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Feb 12, 2012]
    Interesting stuff. So it appears that the TFSI coils may have some performance qualities after all :eyebrows:
  21. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Feb 12, 2012]
    They certainly don't seem to mind a bit of boost that for sure... I am going to be driving the S3 this week to work so will be seeing if they have made any difference to the MPG... the DIS appears to be showing higher numbers than I seem to remember on my normal journeys so looks promising... Fuelly should show this I hope as I could do with closing the gap on the Golf lol...

    <tuffty/>
  22. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Feb 13, 2012]
    Hmmm

    We did some tests on lupo on assorted TFSi, FSi, coils, gaps etc...

    Watch this space whilst I pull all that test data into something presentable..

    teaser..............
  23. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Feb 13, 2012]
    worth mentioning your 20v coils are a few years old currently?
  24. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Feb 13, 2012]
    Well that sounds to me like a set of adapters could be available in time for my Easter build :eyebrows:
  25. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Feb 13, 2012]
    The man has a point :)

    <tuffty/>
  26. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 4, 2012]
    Been a while since an update as tbh I have nothing really to report... I have been gathering bits and bobs and also been teaching myself how to tune ME7 ecu's.... couple of reasons for that... I have a natural interest in the technical side of things (my day job is in IT) and I also like doing everything myself so its a natural progression in the development of my car... plus of course I get to help Bill out and most of all its fun!!!

    I have been collecting bits for inlet manifolds, revised charge pipe work, battery relocation and a larger TIP as I plan to go to an S4 MAF housing (or maybe RS4 depending)... will find some time to get the battery relocated etc soon but will wait until I have some working maps on my car before going down the larger TIP/S4 maf route as I want to get the injectors dialled in nicely and all the fuelling right across the rev range so that hopefully the end result will lead to off boost economy but nice fuelling for power/torques across the range on WOT...

    In the meantime I had a chat with trups (EM Tuning) as I have always wanted to replace the interior lights with LEDs and there seems to be so many types of LED bulb out there that I just couldn't be arsed to sit down and sort it... thankfully trups could be arsed and after letting him know what bulbs were currently in the car he sorted a kit out for me...

    The kit arrived promptly (he sent them out Tuesday and they turned up the following day)... the kit consisted of LEDs to replace the following...
    Front interior lights, front map lights, visor vanity mirror lights, glovebox light, rear interior map lights, boot lights, door puddle lights and door red warning lights...
    [​IMG]

    [​IMG]

    the LEDs were labelled up appropriately to make it a no brainer as to which bulb was for what light...
    [​IMG]

    started off by changing the rear map lights...
    [​IMG]

    ...the difference is fairly obvious...
    [​IMG]

    then did the front interior light cluster... before...
    [​IMG]

    ...festoons replaced...
    [​IMG]

    ....map lights replaced...
    [​IMG]

    ....bit of a difference between the LEDs and good ol' fashioned bulbs...
    [​IMG]

    Its started to rain now so not done the rest but will do a separate write up thread for this once I have done all the others and add it too the interior mods section of the stickies...

    Big thanks again to trups for sorting this so quickly and completely... great service... I am not posting prices up here but suggest if you are looking to do this then head over to EM Tuning and ask trups what he can do for you :)

    <tuffty/>
  27. Rosso TT
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    Rosso TT Member

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    [Apr 5, 2012]
    Tuffty, did you try to turn the map lights on with ignition on and doors closed and see if they work?
    I replaced mine a while back and ended up putting back the standard globes in because the LED wouldn't work, when doors are open they work though.
  28. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 5, 2012]
    Just went out and tried it and works fine... they even fade on and off like normal... :)

    <tuffty/>
  29. beachbuggy
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    beachbuggy Well-Known Member

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    [Apr 5, 2012]
    What have you been learning ME7 tuning wise? Which software have you using...
  30. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Apr 5, 2012]
    The usual mix of Tuner Pro, WinOLS and some other tools Bill has kicking about...

    Been reading through the functional docs and getting my head around the strategies of the ME7's etc... its a different approach for sure but getting my head around it... the logic makes sense to me programmatically and can see why I have had some of the issues I have been having from the way it operates... exciting times :)

    Plan is to get a base map up and running to the basic hardware changes (injectors mainly) running std boost etc and tune the fuelling right, then 'tune' it to the limit of the S3 MAF (360ish hp) playing with various tables etc and then look to add an S4 MAF and 90mm TIP, rescale accordingly and dial in the MAF to get it all running nice... and of course turn up the wick a bit once thats done ;P

    <tuffty/>
  31. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 6, 2012]
    Little update as I haven't really been up to much on my car for a while....

    Mapping is going fine... I have a map on there now thats dialled fuelling wise and currently running my MBC on its own running at 1.5bar to see what comes up fault code wise and how the map handles the measured boost... so far all is good and happy with the way the car drives... I haven't had a chance to get on the dyno yet for various reasons but plan to do so once the dyno is free for an afternoon or two...

    Other stuff planned... battery relocation to the boot... this is so I can have a bit more freedom over charge pipe placement and free up some room for when I go larger on the TIP (either 89mm or 100mm depending what I can fit in there) and still keep the covers for the battery and air box for the OEM look...

    Battery relocation stuff... battery tray, 50mm cable and junction boxes...
    [​IMG]

    One of the reasons I haven't been on the dyno yet is I have a small coolant leak from a hose that only appears when the car is being given hell... I have been waiting for Forge to take delivery of some sets of coolant hoses they have put together as a kit for the S3 and they arrived the other day (big thanks to Kris and Jamie...)
    [​IMG]

    As you can see its a pretty comprehensive kit and I'll be writing that up in a separate thread so it can be bunged in the stickies...

    Thats it for now, need to find some time to crack on and get this little lot sorted and I can then crack on and get this stage of the mapping done... already maxed the MAF at 292.58gs so will be needing a larger one either an S4 one (good for 420hp) or an RS4 one (500+ hp)

    I have not put any timing in either plus I have still to fit WMI (for consistency rather than power)

    <tuffty/>
  32. beachbuggy
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    beachbuggy Well-Known Member

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    [May 6, 2012]
    Looking good as always.

    Ive seen a couple of threads you and Bill have been on where you've mentioned you haven't "put any timing in" could you just elaborate ? Is this against a stick base map or just running your setup and tweaking till no timing pull? I only ask as when ever boost is increased timing has to be taken off, so with your setup now what has been you're base map and I guess your using unisettings to add timing? Does that do it across the whole map? Ie you add 2degrees it does it across all the values or is it just the top load values? And how would this compare to just adding/subtracting timing at specific load/rpm?

    Finally :) with the maf housing are you going to use a specific rs4 housing or just a 4" alloy pipe adapted to take the sensor as I believe that's just as good?
  33. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 6, 2012]
    Currently using the std timing in the KFZW maps... you can run the car up in steady state for part throttle timing additions and do WOT runs adding a few degrees at a time with unisettings (which as you say adds across the whole map) until timing pull occurs and you add timing at the rpms where there is no pull and remove timing from where it is in WinOLS etc... its the sort of thing you can only realistically safely tune on a dyno...

    Adding extra timing is pretty much dictated by the hardware... on fairly std setups with small port heads then you can't get away with much but on large port, big turbo more efficient ve builds you can add extra timing while still running high boost levels... of course its a balance but I have a target boost setting in mind which will be down to total flow of my setup and the rest I can dial in some extra timing... large port heads love it... small ports not so much... think I was running over 20 degrees advance on WOT at peak power rpm's on my last map... plan to do this one on the dyno though to try and gain every where... timing advance is free power but... and its a big BUT!... it must be done carefully as if you over do it then its bye bye engine...

    Whatever housing I go for I will use the OEM tube and sensor... few reasons...
    1) its easy to replace the sensor (cheaper as its normally exchange)
    2) I can just use the already preconfigured scaling from an RS4 map as a base for the map as airflow is airflow regardless of if its a 1.8 4pot or 2.7 6pot drawing it in
    3) OEM tubes have the screens in place for laminar flow reasons and are already a pre-calibrated device... why bugger about with all the work VAG has done :)

    I/D of the RS4 maf tube is 83mm... 100mm is a hell of a lot different and will be an arse to calibrate... as I don't need that size at my power level then its not really worth making more work for myself tbh... going 89mm or 100mm TIP is purely down to what size pipe and hoses are available...

    Plus this looks cool...
    [​IMG]

    [​IMG]

    <tuffty/>
    Vagworld likes this.
  34. beachbuggy
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    beachbuggy Well-Known Member

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    [May 6, 2012]
    Cool understand re timing. I guess as you have a boost figure in mind that must be easier to tune to than trying to balance, boost v timing !

    My mistake over the maf, for some reason I thought the rs4 maf was 4", but obviously not and yes using the stock rs4 maf table would be far easier than re calibrating a whole table.
  35. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 6, 2012]
    Max boost will limited to the hardware and total flow... I know the limitations of my setup and know that more boost doesn't equal power (this is the same of any setup tbh)... no point in increasing the boost if the engine doesn't have the ve to consume it...

    My engine ve will improve once I have sorted the charge pipes out and changed the inlet manifold but I know the limiting factor in my setup will be the log manifold I have.... at some point I may look to change it to a tubular one but then I may well change my turbo too if thats the case...

    Always a learning curve in this game... no one setup the same and different setups that surprise you as to why they do more (or less) than you thought they would...

    Recent LCR we had in with a stroker kit, ported large port, HTA 3071 (billet comp wheel), TSR tubular mani and a Tial 0.82 vband hot side was a fantastic setup... over 460hp and 390ftlbs at 28psi peak tailing to 24psi... it had 20psi at 3.5k rpm!! nice bit of kit :)

    <tuffty/>
  36. Andrew@A.L.D
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    Andrew@A.L.D May add NOS to 600+bhp?

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    [May 6, 2012]
    Sounds good

    I'm getting excited about my mapping on Tuesday now so hope to see 500+ with 30+psi ish
  37. Rosso TT
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    Rosso TT Member

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    [May 7, 2012]
    Hi tuffty, i might have messed this point, is the RS4 maf sensor different as flow wise to the S3/TT?
    Say, you have the same diameter housing for both sensors, is the RS4 sensor measuring more flow than S3/TT?
    Cheers
  38. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 7, 2012]
    You have missed the point a tad yes lol ;P

    The sensors do have slightly different response curves but its more the diameter of the MAF tube that plays the part...

    MAF sensor 101.... the MAF sensor is a hot film type sensor that measures airflow based on how much current is required to keep the sensor element at a certain temp... the faster the air moves over it the more current is required to heat the element... this is converted to a 0-5v output that the ECU will under stand..

    When airflow exceeds the measuring capability of the sensor (ie is moving so fast the output is pegged at 5v) then the only way to measure this extra flow is to lower the speed of the air passing over it... larger MAF tube will allow the same volume of air through at a lower speed than a smaller tube and therefore still fall in a measurable range...

    So, in summary... to measure more airflow you need a larger MAF tube... you could in essence use the S3 sensor in an RS4 tube but... the scaling in the maps is setup for the RS4 sensor/tube combo and its an off the shelf part to replace when the sensor dies (as they do) so its a no brainer in that context...

    <tuffty/>
  39. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [May 8, 2012]
    Good Luck with your mapping andrew
    should be a monstor :D
  40. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [May 13, 2012]
    Found a bit of time inbetween jobs today to prep the AEB runners for making a larger inlet manifold..

    It started life as...
    [​IMG]

    Cut the runners off (roughly as they will need trimming when I offer it all up in the engine bay)... I also flushed the cast marks on the runners and removed the spare boss for a brace or something on the AEB...
    [​IMG]

    ...close up...
    [​IMG]

    I am getting the runners blasted to clean them up and I have trimmed the plate ready for the runners holes etc...

    I have some time off soon to get a load of jobs sorted... doubt I will have the inlet done just yet but battery relocation and coolant pipes will get done and will get some time on the dyno to do some more work on my mapping...

    Flashed a new map in today as I have made some changes to smooth out the idle and dial the injectors in a bit better... seems to have worked :)

    <tuffty/>

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