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S3 PE1820 big turbo build

Discussion in 'A3/S3 Forum (8L Chassis)' started by Welly, Mar 29, 2011.

  1. mk1chopper
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    mk1chopper Missing the S3

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    [Jun 1, 2011]
    Into the space where the SMI were as there should be some air flow here and maybe vent the wheel arch liner to aid in air flow or stick a magic tree at the end of your current outlet
  2. Welly
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    Welly VX220 SC Driver :)

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    [Jun 1, 2011]
    I agree with you on that one, down in the front bumper/wheel arch area looks to be the winner in all honesty. That is most likely where I will be looking to put it.

    The problem with the smell of crankcase vent fumes is that they really are putrid. Horrible ++
  3. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jun 1, 2011]
    You need some of Bill's (slightly) expensive Motul race oil... smells like sweets :)

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

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    [Jun 1, 2011]
    With a healthy engine, how much of an issue will it really make having the fumes vented back into the intake?

    Have you tried comparing figures on the dyno with and without it?
  5. Speedy Steve
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    Speedy Steve Active Member

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    [Jun 1, 2011]
    Know if it was bubble gum smell id vent it into the cabin lol
  6. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jun 1, 2011]
    depending how "fumey"/worn the engine is will depend on the oil fume oil content and ability to degrade the effective octane
    shagged engines, which injest their own oils and fumes pull a lot of timing...

    case by case

    on one not smoking like a trooper, I cant say I notice any more timing pull or dyno difference, but over time those which do rebreath their fumes will gather oil in the charge pipes more.
  7. Welly
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    Welly VX220 SC Driver :)

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    [Jun 1, 2011]
    Well, did several things when I got home from work.

    Firstly, installed a nice new pipe for the breather. Sits way back from where it did before, and is definitely much much better. Good start.

    Secondly, took plugs out and checked them for colour. A lovely golden biscuit brown. Just the job.

    Lastly, installed D07 nozzle and took out for some logs. Still getting more timing pull than ideal seeing up to and including 6s, but nothing to write home about. My inlet temps aren't as low as I was expecting either. I will need to compare today's log with the ones bill has from dyno runs, as well as manually test the WMI setup.

    It seems that my MAF is incapable of reading anything higher than 280.33. I have NEVER seen the figure get above that, and these logs today demonstrate that, despite it hitting 280.33 at 7K RPM with another 800+ RPM to go... and then it just repeating that figure. Seems a bit strange.

    Anyway, all is well, however I suspect that my WMI pump my be on the way out.... Boooo. Oh well, time for a new 120 PSI one me thinks...

    A quick extract from the D07 log:

    Code:
    
    	Group A:	'002				Group B:	'011				Group C:	'020			
    		RPM	Load	Inj. On Time	Mass Flow		RPM	Temperature	Temperature	Ign. Timing			TIME					TIME					TIME				
    Marker	STAMP	 /min	%	 ms	 g/s	STAMP	 /min	°C	°C	 °BTDC	STAMP	 CF	 CF	 CF	 CF
    2nd	379.62	2560	19.5	1.23	10.75	380.02	2600	89	20	36.8	380.51	0	0	0	0
    	381.01	2600	24.8	1.64	12.25	381.5	2600	89	20	36.8	381.9	0	0	0	0
    	382.3	2640	25.6	1.64	12.44	382.7	2640	89	20	36.8	383.1	0	0	0	0
    	383.5	2720	32.3	2.05	17.19	383.9	2800	89	20	36	384.3	0	0	0	0
    	384.7	3040	58.6	3.28	35.14	385.1	3200	89	21	33	385.51	0	0	0	0
    	385.9	3760	112	6.15	84.44	386.3	4160	89	21	24	386.7	0	0	0	0
    	387.1	5440	191.7	14.35	250.75	387.5	6120	89	21	19.5	387.9	0	3	5.3	1.5
    	388.3	7320	191.7	12.71	280.33	388.7	7800	88	21	8.3	389.1	0	0	0	0
    3rd	389.5	5520	175.2	11.89	196.61	389.9	5800	88	20	16.5	390.3	3	5.3	0.8	6
    	390.7	6440	191.7	14.35	276.53	391.1	6720	88	23	15.8	391.6	3	5.3	0.8	5.3
    	392	7320	191.7	12.71	280.33	392.51	7560	87	24	18.8	392.91	3	3.8	0.8	3.8
    	393.31	7240	27.8	2.87	63.31	393.71	6040	87	21	15.8	394.09	0	5.3	0.8	6
    4th	394.49	6360	191.7	13.94	272.67	394.89	6480	86	26	15.8	395.29	0	5.3	0.8	6
    	395.69	6760	191.7	13.94	279.72	396.09	6880	86	27	16.5	396.49	0	5.3	0.8	6
    	396.89	7120	191.7	13.12	280.33	397.29	7200	86	27	17.3	397.69	0	3	0.8	3.8
    	398.09	7440	191.7	12.71	280.33	398.49	7520	86	28	19.5	398.89	0	1.5	0.8	1.5
    	399.29	7680	191	12.3	280.33	399.69	7720	86	29	6	400.09	0	6	0.8	6
    
  8. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jun 1, 2011]
    The MAF thing seems the same sorta thing as mine hitting 292.58 and going no further... not seen Bill's logs on your car so maybe its always been there...

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

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    [Jun 1, 2011]
    Doesn't always track mate... EGT's at high RPM can still be reasonable and defo lower than a K04 flat out... IAT's on the log aren't too bad either so not silly at all... my logs as a comparison...

    [​IMG]

    Similar IAT's and I am not running WMI...

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

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    [Jun 1, 2011]
    The MAF thing is seen on S4's as well, Vagcom maxes out at some value around 300, the exact value depending on the exact ECU revision, even though the MAF itself isnt maxed out as far as the ECU is concerned, its just the vagcom output that pegs.

    The Absolute max for the S4 MAF is apparently 364g/sec however Vagcom can peak at anything between 310 and 330 depending on which ECU the car has.
  11. Welly
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    Welly VX220 SC Driver :)

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    [Jun 2, 2011]
    Exactly, I used to see IATs drop down to ambient temp when WMI was running. I will have to whip the bumper off and bench test the WMI I think.
  12. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jun 2, 2011]
    On tufftys S3 maf, it is pegged at 4.98v for its 292g/s figure
    S4 maf may be required on tufftys.

    will have to check wellys ecu code for its current maf scaling. Its stock as it tufftys currently.
    you can scale in software the g/s against voltage, but the maf sensor voltage being max'd is the issue on Tufftys, and *might* be the case on Wellys also.. Might need to physically hang the dvm off the sensor output again to confirm voltage. (like I did on tufftys way way back)
  13. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jun 2, 2011]
    from the logs I would think its no workie mate :(
  14. Welly
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    Welly VX220 SC Driver :)

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    [Jun 2, 2011]
    It's certainly looking that way. However, on the plus side, I now know that I can run out of WMI without any bad side effects.... Timing pull is within tolerance.... Mwhahaha (Rub hand with glee).

    I thought I wasn't using much meth lately....
  15. Dane
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    Dane Faster than a V12 Q7

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    [Jun 2, 2011]
    I can empty 2/3 of a tank on an evening drive... :crying:
    Speedy Steve likes this.
  16. Welly
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    Welly VX220 SC Driver :)

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    [Jun 2, 2011]
    I thought that meth consumption was just much better than the hybrid, due to being off the boost more.

    Turns out the WMI is just shagged. Booooo.

    Talk about a let down.... :lmfao:

    However, as I said, a successful test. Glad to know that if this were to happen again, the thing won't blow up from massive CFs.
  17. Speedy Steve
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    Speedy Steve Active Member

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    [Jun 2, 2011]
    I need WMI in my life Bill you have a PM!
  18. Welly
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    Welly VX220 SC Driver :)

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    [Jun 2, 2011]
    So do I it would seem..... lol
  19. MUSH
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    MUSH MUSH Developments Ltd.

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    [Jun 2, 2011]
  20. Welly
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    Welly VX220 SC Driver :)

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    [Jun 3, 2011]
  21. Welly
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    Welly VX220 SC Driver :)

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    [Jun 3, 2011]
    The problem wasn't that the meth wasn't working, it appears that it was just set to fir up too late.

    The meth was originally set up to come on at 12 PSI, however when tested, it didn't switch on until 18 PSI. The issue there is that it is trying to cool something that is already very hot, as opposed to stopping it getting so hot in the first place.

    Timing CF is back down to 3's where it belongs which is nice. I still think I need a new pump as mine is leaking. I may well get one which is a slightly higher pressure this time...
  22. Welly
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    Welly VX220 SC Driver :)

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    [Jun 3, 2011]
  23. Dane
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    Dane Faster than a V12 Q7

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    [Jun 3, 2011]
    Mine says 200 psi on it... whether that actually means what you mean I dont know lol.
  24. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    [Jun 3, 2011]
    nice find on pumps welly
  25. Welly
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    Welly VX220 SC Driver :)

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    [Jun 3, 2011]
    Yeah, the AEM ones are 200 PSI which gives a really nice fine mist. My current one is only 100 PSI, and it leaks, so probably isn't 100 PSI anyway....

    Yeah, I thought they were a bargain. Same design as the Sureflo ones, but just nowhere near the money.
  26. Welly
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    Welly VX220 SC Driver :)

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    [Aug 8, 2011]
    Well, over two months have been and gone now since completion.

    I've done a great many miles as well since.

    Nothing to report really. Still goes really well which is good!

    I did bend :)scared2: ) the bolt that holds the dog bone mount to the gearbox, which was a bit of an issue... Not really sure how, but I guess it must be the savage beatings she gets.

    Also, on the way back from Kettering yesterday, I did snap one of the engine mount bolts cam belt side which is a bit of a pain! New ones sorted though, got to collect them in an hour.

    Nothing else to report though, apart from the biblically bad fuel economy....
  27. Speedy Steve
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    Speedy Steve Active Member

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    [Aug 8, 2011]
    Good to hear she's running well mate. Shame the weather turned **** yesterday or i'd have stayed around longer
  28. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Aug 8, 2011]
    Welly I would love to do the engine build you have, I was mighty impressed when you took me out for a spin.

    That's some savage torque to bend and snap mounting bolts!!!
  29. Welly
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    Welly VX220 SC Driver :)

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    [Aug 8, 2011]
    Its all well and good doing this sort of thing, but it's the lack of longevity in the supporting parts that you don't think about at the time.

    For example, the rear doughnut on the prop had some bolts go snapola due to torque delivery to the rear end, it also mashed the doughnut out of shape.

    Engine mounts the same, they have to cope with, and retain all the engine movement under load which is a hard job I guess.

    I love it don't get me wrong, but it's the little things like this that you don't think about at the point of build.
  30. Welly
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    Welly VX220 SC Driver :)

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    [Aug 8, 2011]
    Thats cool mate, no probs. I wasn't hanging about in an empty field in the rain either believe me.
  31. Dane
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    Dane Faster than a V12 Q7

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    [Aug 8, 2011]
    Lol my list after getting the gt30 on is now,

    Vibratechnics mounts
    then SEM lol.
  32. Sandip
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    Sandip Well-Known Member

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    [Aug 8, 2011]
    Good to hear the car's running well bud! I caught a glimpse of it yesterday, i was leaving Wicksteed Park as you were driving in, car looks mean!! :racer:
  33. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Aug 8, 2011]
    steady on ;)
  34. Welly
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    Welly VX220 SC Driver :)

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    [Aug 8, 2011]
    My engine mounts themselves are fine.

    It's the bloody bolts between them = fail.

    SEM is some thing I really want too mate I must admit.... It's the last thing I feel I actually need.
  35. Dane
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    Dane Faster than a V12 Q7

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    [Aug 8, 2011]
    Having spoken to Bill about it the other day I'm going to use a SEM as a continuation of the project in an attempt to keep the initial cost down.

    Is it worth getting a SEM if you're moving on?
  36. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Aug 8, 2011]
    I would hazard a gues that these are causing that nice characteristic clunk you have mate.

    TT ok now?
  37. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Aug 8, 2011]
    Stop it with all the mods boys pleas! I've just got my list of things to do right down and my eBay watch list only has 1 thing left. It's time to buy a house for me.
  38. Welly
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    Welly VX220 SC Driver :)

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    [Aug 8, 2011]
    Quit your moaning, you can do that as well.... :eyebrows:
  39. IbanezDan51
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    IbanezDan51 Member

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    [Aug 12, 2011]
    Hey Welly looks like this is producing some nice results now! Bet you are glad to be rid of the hybrid ko4....

    You are running a similar RPM to me but a bit less torque - I was near 350lbft with a 7900 RPM limit before I killed the head and gave up. If/When I build another 1.8t I would do the valves and springs - suprised you haven't been a bit on edge running that sort of RPM range and those levels of boost at such high rpm.

    Hope everything continues succesfully! OW and I was using one of those OBX manifolds - but a large port one which I found in this country. I lost mid range torque but it did help develop a few more horses top end for those willy waving rights lol.

    Dan

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