Edgar's A4 B7 2.0TFSI BT Build

[i3oricua]

Hmm Ok well that in theory replicates the factory I guess, my only other thoughts are what size is all the pipe work compared to the factory ?

It could be that your pipe work is restricting air flow causing the pressure build up. Also how often to you check and empty the can itself? It could be that there’s quite a bit of oil in there and so it can’t ‘catch’ any more so it just spits it back out?

Generally the only way an engine smokes is if there is oil getting into the combustion chamber, you’ve eliminated rings and valve stem oil seals by fitting your factory cover set up, and that’s pin pointed your custom set up. I think it’s worth trying to compare every little detail that the factory set up has compared to custom and seeing what the difference is. Is there a restriction anywhere that’s causing a higher pressure build up?

Maybe the custom cover has a valve in it that’s blocked or partially blocked? Or is there something from the factory set up that you can in cooperate to the custom set up that will stop or reduce the oil flow?


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All the lines are 10an lines. They’re as large if not larger than the factory setup. The can is only about 2-3 weeks old. Possibly could have some sludge in there, worth checking since it’s been colder and wet and that’s when they tend to fill up the quickest. The custom valve cover is simple in nature. There’s nothing to get blocked or restricted. If you check out Integrated Engineering’s site or search the image you’ll understand why I say that. I’ve already put a new oil drain line from the turbo so that’s ruled out as well. Definitely no restrictions anywhere.

It’s something I have to live with for now until work out if or how to tap into the vacuum pump without effecting my brakes since it also runs off that pump.


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[Stickystuff]

Have you contacted them about your issue? They might know what you can do, or on the other hand see if there is anything they can develop seeing as it’s a product they sell.

Hopefully they are a decent company and at least try and help you out


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[i3oricua]

Have you contacted them about your issue? They might know what you can do, or on the other hand see if there is anything they can develop seeing as it’s a product they sell.

Hopefully they are a decent company and at least try and help you out


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That’s not a bad idea. I know I’m not the only one with this problem so they may have a solution worth trying. They seem like decent people so it’s worth a shot.


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[Charlie Farley]

What I will say about the mishi tanks is this, The micron filter that is built into the top section does get clogged very easily and can cause back pressure.
it needs a thorough clean on a regular basis with the tfsi engine, whereas on other engines it may not.
In all the time I had the setup fitted to my old bus I had no issues at all, ran spot on , I did have the clogging issues hence why opted to clean it every month.
The problem with this routine is that the top section is not really designed to be removed on such a regular basis , the can itself yes but top no so.
Over the period I had the can fitted I did come across several issues that were design flaws but resolved them quite easily.
I have since removed that setup for my newer revised kit , but like I say in the time I had it installed I suffered no adverse engine conditions, quite the opposite really the engine ran very well.

 

[Charlie Farley]

from my pcv thread.

 

[Charlie Farley]

But that said it shouldn't be an issue for you Edgar as its a nearly new install, if it was clogged already I would be a bit concerned why.
There are only a few ways oil can get into the combustion cycle, as you have rebuilt the engine top down that list has pretty well reduced to only one.

 

[Charlie Farley]

Just to add a twist to things, you noted the smoking on idle with the oem pcv setup aswell , as you have it with both oem and aftermarket setups that would suggest something else is happening.
Whats is your oil consumption like?

 

[i3oricua]

Just to add a twist to things, you noted the smoking on idle with the oem pcv setup aswell , as you have it with both oem and aftermarket setups that would suggest something else is happening.
Whats is your oil consumption like?

I did read over your PCV thread but only the first few lines so I definitely missed that part you spoke about the Mishimoto can. I’ll have a look at the can today to see if it’s got crud in it already.

The OEM setup worked really well. No smoke, just some idling issues which I could have worked out over time but didn’t get around to it because the new van arrived. I do think it was probably eating some oil but I couldn’t tell to be honest because I had sprung an oil leak because when I did my oil change I put the oring oil filter housing on upside down (yes you can put it in upside down, news flash to me) so I was losing oil that way. Just recently fixed that. I suspect that if I removed the intercooler and piping I would find some oil in there from the stock setup.


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[Charlie Farley]

What sort of manifold vacuum figure do you have at idle Edgar.

 

[i3oricua]

What sort of manifold vacuum figure do you have at idle Edgar.

Honestly I don’t know.


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[Charlie Farley]

Just curious really , maybe there is too much vacuum which is sucking up excessive oil vapour from the primary oil separator.

 

[i3oricua]

Just curious really , maybe there is too much vacuum which is sucking up excessive oil vapour from the primary oil separator.

That may be true also but I don’t know how to test that theory. I did empty my catch can today and surprisingly it had more in it than I expected. It’s also a small catch so it doesn’t take much. Smoke didn’t go away though, insert whomp whomp sound here.

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[Charlie Farley]

That's a lot Edgar for only a short time, how long has the tank been connected.

 

[Charlie Farley]

This was my first empty before I fitted the drain pipe/tap, a few weeks worth if I recal.

 

[i3oricua]

That's a lot Edgar for only a short time, how long has the tank been connected.

Maybe 2-3 weeks? I know when it’s colder and wetter the can will fill up quicker. Like I said, it’s a small van so it doesn’t take much. Gonna have to check it every payday or something to stay on top of it.


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[Charlie Farley]

But on the plus side, just think how much better your engine will be without all that being dumped back into the engine , contaminating your sump oil and intake valves etc.
It would be nice to sort the idling smoke out aswell though so you then have a 100% .

 

[i3oricua]

Took the HPFP off to check it and the cam follower. Everything looks fine there. I’m starting to think that either I need to figure out the PM4 more or the JHM Walbro pump I bought is already going bad. I’ve read a few things on the DW300 failing pretty early but mainly on the STI forums. I’m leaning more towards the controller needs fine tuning.

Also, since I’ve kept in top of draining the Mishi can my smoking is almost non existent. Hope it stays that way. It’s such a small can that it’s something I’ll have to do every week. It still stinks in the car and I wish I had a better solution besides putting the stock system back on. Still avoiding doing that.

And one out in the wild because the scenery is gorgeous around here.

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[Charlie Farley]

Glad your making progress Edgar,
Just curious how you have the catch tank connected now , you should be getting zero odour in the cabin from the pcv if it's a closed system.

 

[i3oricua]

Glad your making progress Edgar,
Just curious how you have the catch tank connected now , you should be getting zero odour in the cabin from the pcv if it's a closed system.

It’s still the same as it was before. I’ll have to take a pic of the finished setup and post it.


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[Charlie Farley]

If you are getting pcv odours in the cabin you must have a leak somewhere in the pcv setup Edgar, or an oil leak that is burning off and you can smell it in the cabin.

 

[i3oricua]

Bought these B pillar thingy’s from a guy for a really good price. Very happy with them. One of the easiest things I’ve ever installed.

Got my second tune file. Nothing major because of my fuel cuts up top. Still need to figure that out. I think I either have a leak at the fuel pump from one of the lines at the basket or the pump was bad from the get go and is already failing. For reference it’s a DW200.


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[tr7]

Mega build! Makes me want a petrol.

Have to ask Edgar, are you US serviceman or RAF?

 

[i3oricua]

Mega build! Makes me want a petrol.

Have to ask Edgar, are you US serviceman or RAF?

Thanks!

US serviceman.


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[i3oricua]

New Walbro 450 arrived from Summit yesterday so I installed it today. Used my existing JHM kit that came with the DW200 and modified it slightly to fit the 450 and it seems to have worked just fine.

Duty cycle dropped from 70’s and 80’s to low 50’s and high 40’s at idle. I’ve read a couple of not so goods about the DW’s and I seemed to have been a victim of it too. Don’t know if the pump is capable of big turbo builds but I’m confident the 450 is. Install pics below:

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[Charlie Farley]

Getting there Edgar.

 

[i3oricua]

It's been a while since I provided an updated. So I've ordered some things and installed one or two things. Really just been chasing codes and working with Dave to get the fueling right. I bought what I thought was a 155 bar PRV from a guy and it turns out that it cracks at 140 so we can't get fueling past that right now. So I've ordered a 175 bar PRV from a company here in England. Should be a few weeks since they're making them as we speak. When that comes in, it'll be a quick install and then we can throw more fuel at the motor. I'll have to keep an eye on the cam follower as the fuel pressure goes up or find a different solution. Might do the Golf R cam since it adds more lift and takes some of that pressure off the cam follower and HPFP. I've also ordered an addition to my meth setup to put a nozzle on each port. We'll see if it was worth it down the road.

Today, while logging for the 5th file that Dave has sent me I came up behind what I believe was an RS4 Avant. The only badge it had on it was MTM on the bottom right. I wasn't sure if he wanted to play but you can see in the video below that he smashed the gas on me and I tried to go with him but he just kept pulling. That was only through 3rd gear and a little bit of 4th. We both let off and a few miles later down the road we gave each other a thumbs up. He had to be 50 or 60 years old....my kind of guy.



Anyways, really looking to getting this new PRV and seeing what Dave can do with more fueling to work with. I know there's the cam follower/roller conversion but man that's an expensive option.

 

[Charlie Farley]

It's been a while since I provided an updated. So I've ordered some things and installed one or two things. Really just been chasing codes and working with Dave to get the fueling right. I bought what I thought was a 155 bar PRV from a guy and it turns out that it cracks at 140 so we can't get fueling past that right now. So I've ordered a 175 bar PRV from a company here in England. Should be a few weeks since they're making them as we speak. When that comes in, it'll be a quick install and then we can throw more fuel at the motor. I'll have to keep an eye on the cam follower as the fuel pressure goes up or find a different solution. Might do the Golf R cam since it adds more lift and takes some of that pressure off the cam follower and HPFP. I've also ordered an addition to my meth setup to put a nozzle on each port. We'll see if it was worth it down the road.

Today, while logging for the 5th file that Dave has sent me I came up behind what I believe was an RS4 Avant. The only badge it had on it was MTM on the bottom right. I wasn't sure if he wanted to play but you can see in the video below that he smashed the gas on me and I tried to go with him but he just kept pulling. That was only through 3rd gear and a little bit of 4th. We both let off and a few miles later down the road we gave each other a thumbs up. He had to be 50 or 60 years old....my kind of guy.



Anyways, really looking to getting this new PRV and seeing what Dave can do with more fueling to work with. I know there's the cam follower/roller conversion but man that's an expensive option.

Us old guys (50 -60) are really all 25 years old inside, its called growing old disgracefully but we all like performance cars and the rush.

 

[i3oricua]

Us old guys (50 -60) are really all 25 years old inside, its called growing old disgracefully but we all like performance cars and the rush.

Absolutely right Rob and one day that will be me as well.


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[i3oricua]

Some things have arrived in the last few days finally. Golf R intake cam

And my Devil's Own port meth injection kit. I've got a spare intake manifold so I've already installed the nozzles on it. The missing nozzle is currently on the car but the whole is already filled and tapped.

Final thing is the 175 bar PRV that I ordered. I called AKS Tuning today and told them I'm coming to their shop on Friday to grab it. They've been dragging their feet on it some. Regardless, I leave on Sunday for a month so unless I install everything Friday night or Saturday I won't get to enjoy until I get back in March so I'll just wait some more.

Last thing is I sprayed the stock valve cover with some bed liner spray and it turned out really great. Simple things sometimes make me happy.

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[i3oricua]

Finally back in town. Got my 175 bar PRV and some ARP flywheel bolts. I'm pretty sure I have a slow leak from the rear main seal so I'm gonna attempt to drop the transmission this weekend and fix that along with the new PRV, the manifold with the direct port injection, and the Golf R cam. Hopefully I'm able to get it all done.

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[Ricky Burrows]

Finally back in town. Got my 175 bar PRV and some ARP flywheel bolts. I'm pretty sure I have a slow leak from the rear main seal so I'm gonna attempt to drop the transmission this weekend and fix that along with the new PRV, the manifold with the direct port injection, and the Golf R cam. Hopefully I'm able to get it all done.

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Your back in England now mate wheres your socks with those sandals brother?

 

[i3oricua]

Your back in England now mate wheres your socks with those sandals brother?

LOL. Yes. Just got back today after traveling for about 14 hours. Long two days of flying.

It's not that cold plus I was just in the garage checking out my parts and trying to make sure I have everything I need for what I hope is productive weekend.

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[Ricky Burrows]

LOL. Yes. Just got back today after traveling for about 14 hours. Long two days of flying.

It's not that cold plus I was just in the garage checking out my parts and trying to make sure I have everything I need for what I hope is productive weekend.

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Hopefully more productive than my last weekend i did springs on the mrs car Saturday, Oil cooler and full service sunday then found it had a hole in the radiator but not until after it had overheated and blown the head gasket thanks to vauxhalls great idea of not having a water temp gauge as standard, so new radiator on Monday, manufactures recon engine ordered Tuesday not good as were going on holiday in it at the start of next month.

 

[i3oricua]

Hopefully more productive than my last weekend i did springs on the mrs car Saturday, Oil cooler and full service sunday then found it had a hole in the radiator but not until after it had overheated and blown the head gasket thanks to vauxhalls great idea of not having a water temp gauge as standard, so new radiator on Monday, manufactures recon engine ordered Tuesday not good as were going on holiday in it at the start of next month.

Wow. That's an expensive set of circumstances. Hope you're able to get it all sorted out. That's interesting that there is temp gauge. Smooth design.

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[Ricky Burrows]

Wow. That's an expensive set of circumstances. Hope you're able to get it all sorted out. That's interesting that there is temp gauge. Smooth design.

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Yeah i know great design ay something else ill have to fit for future peace of mind.

Anyway hope it all goes smoothly on your car

 

[i3oricua]

Took the trans off today to check rear main seal. I used bolts that were too long on it which I believe was causing some slow oil leakage.

While I was there I put ARP bolts on the flywheel. Really unnecessary but I won't have to buy new ones again if I have to take those off in the future.

Also changed the slave cylinder to a metal one.



Clutch looks pretty good except for a strange spot on the pressure plate. I get vibrations in first and reverse when letting out the clutch. I'll check it with a straight edge tomorrow and make sure it's not warped.

Tomorrow, trans back in and hopefully get to the new cam, manifold, and 175 bar PRV.

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[i3oricua]

Got the trans back in yesterday and everything buttoned back up. Didn't even start the PRV or cam job. I'll just start this week and be done by weeks end hopefully. Think tonight after work I can get most of it disassembled although not all of it. Finish maybe Tuesday with disassembly and some of the install and hopefully no later than Thursday be back on the road and the new map loaded. Dave from Motoza has already sent me the new map for the cam and bigger PRV so once everything is in I can flash the ECU and do some logging.

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[i3oricua]

Got moving along tonight. Pulled the manifold, HPFP, and vacuum pump off. Tomorrow I should be able to get the cam off and the new one in and some reassembly done. Only worked for an hour and a half today so I'm happy with what I was able to get done.

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[i3oricua]

Got everything on over the weekend. New intake cam on, check. New PRV on, check. New meth port injection ok on, check.

Took the car out to get my haircut before I flashed the new file and I got a hard cut around 6K RPM. Checked codes and nothing there. Did about 3 times total and no codes. My guess is it's because of the new cam. Flashed new file to account for PRV and cam last night but haven't driven it since. I have to do some logging and it was raining. Don't want to take a risk on really wet roads. Hopefully today I can do some logging and get it over to Dave.

Edgar

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[i3oricua]

So I've done a few logs but I can't get past about 5300 RPM without getting some hard hesitation and cuts. There's no codes that I'm getting even with a scan with VCDS. I checked timing through VCDS as well and it was dead on I did have one hiccup on install and it was I didn't have the PRV tigthened enough so I was leaking some fuel there. Luckily that turned uneventful. So I tigthened everything up and went to do some logging after work and am still getting hesitation. I actually think it's because of my new meth setup and it's spraying too much too early. I'll adjust the controller tomorrow and take it for a spin again. Hopefully that works. If not I'll just send the log to Dave and see what he sees in the data.

I also received my cam roller conversion and will install that this weekend. Fairly easy and straight forward.

I also installed a new cone filter since the old one was a bit dirty and gummed up. This one should be easy to clean too when it gets dirty.

Edgar

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