Let the tinkering get serious!!....

[Greg Roles]

...and the afternoon has been a big success, the cold side intercooler plumbing has gone in almost too easily! A 42DD MAF mount ( off the shelf thanks very much ) and a bit of bead rolling and it's ready to finalise the hook up tomorrow for a test run! Had to lengthen the MAF plug wires, but apart from that it's been clear sailing for once. Just hope it starts! If it works OK, I'll pull the EGR system entirely next, and start on the exhaust. Yay!

You've seen the hot side before...I upgraded the mounts a fair bit from what I tried last time.....








But here's the new cold side with the meth inlet just after the IC outlet!

[sabloke]

This thread almost makes me wanna go back to Diesel Can't wait to see how she runs!

[Preen59]

Methanol is about $1.00 a litre at the moment. We paid a little less for our last drum. If you were closer I'd be happy to sell to you. haha.

Nice work, man. Loving it for sure. I'm keen to see how the water/meth goes. I'm thinking I might try a throttle switch setup with a windscreen washer pump on the GLD at some stage to see what it does..

[Greg Roles]

This thread almost makes me wanna go back to Diesel Can't wait to see how she runs!

I'm actually just hoping it DOES run!!

Already planning my exhaust, need a TIG welder!

[benough]

So did it start?

[Greg Roles]

Awaiting a longer 45 degree silicon coupler, today hopefully, then it's crank time.

It'll start, question is will it run with/without CEL's, and how will regen go without the stock flapper?
Put in the 42DD O2 spacer yesterday, should limit the CEL's hopefully.



The good news is as the USA are now suffereing DPF's on their TDI's and they are already onto developing aftermarket solutions. I am hopeful they will provide better DPF options, as I do want to keep one long term, but a cheaper, rebuildable, higher flow, less invasive regen one. The new MK6 has split the cat and DPF apart, thus lowering the cost of DPF replacement. That's GREAT news, and the path I would go if the DPF clogs and you want to stay OEM, retrofit the MK6 system.

[Greg Roles]

So did it start?

[benough]

aahhahaha so how does it go?

[Greg Roles]

Well I finally took it for a decent run to allow the regen it had been stopped with to complete, and to see what happened. As I am still awaiting the correct 45degree silicon coupler in the post and had to temporarily make up a suitable join yesterday, I wasn't game to really flog it - and I was worried about the error codes / regen. I've popped enough silicon couplers already thanks!




Well it starts and runs fine, seems to be a little louder induction wise, but not as bad as I expected. I drove it carefully till the regen kicked in once warmed up, and it ran fine for about the normal 10 mins which absolutely amazed me. Temps on my EGT were as per normal, couldn't believe my luck. Then as it finished it threw an error code up and the coil light started flashing, which really freaked me out. I pulled over and checked under the hood, looked at all the gauges, and it all "seemed" fine, so I kept going carefully. I stopped up the top of a hill as I thought I heard something drop out of the engine bay like a bolt or something, and I was already on high alert, so I pulled over. It all seemed fine and I couldn't see anything on the road. Started her back up and the coil light had gone away, but on the way back the engine shaped light CEL illuminated, but it continued to run as per normal.

A VagCom once back home showed the engine symbol CEL to be the typical "insufficient EGR" and that's to be expected, as now there's none at all. The earlier coil CEL was " Mass Air flow during Regen too low" and that makes sense as I have removed the flap that part closes during regen to help the DPF reach higher temps.



I can part close my QTP flap, but will monitor my soot loads via VagCom, and force some regens if it gets too loaded. The EGT gauge tells me it is reaching suitable temps, just the ECU isn't seeing the increased airflow speed with the closed flap during regen. Will have to find a way to make this work as HOLY COW does it feel much meatier to drive now!

Errors and potential problems aside, it feels quite different, and I haven't even given it the berries as yet. Before the turbo would spike at 23-24 psi and then settle back down towards 20 or so. Now it spikes at 21-22 and stays there, no more peak and drop off! It feels like the normal 1800rpm wack, but then just doesn't let up, friggen amazing for a still stock ECU and exhaust. Very noticable, fatter mid range, can't wait to give it an all out effort. I figured that flap / EGR body was restrictive, but WOW, I didn't expect that much difference on the stock exhaust. Really can't wait to get onto that now, and then get her tuned. ooo baby!

Once I sort out the DPF loading / regen thing, I'll get some Methanol and add that to the equation. Must say I'm excited!!!

[benough]

Wow, you've finally done it.

If you know what the errors codes mean then I think you've done a good job and all the hard work is over.

In other news my car went into limp mode at the top of third entering the motorway this morning. I sometimes get the flashing coil light before I kick it over. meh

It's been booked in for a while now, hopefully they'll sort it out

[poyta]

Must say I'm excited!!!

Me too Greg, well done.

[Greg Roles]

I've hooked up a switch to be able to alter the QTP flap, so I'll try and force a regen and play with the flap position till I get the magic 700 degrees pre turbo on VagCom. It's going to keep throwing errors, but so long as I keep an eye on the DPF soot levels, and force regnes if need be, it should be all good in my mind. Seems the lappie is going to be my passenger for a while......as there's no WAY I want to go back to stock, can't wait to get the right silicon joiner in the post ( probably tomorrow when I am in Cairns all day ) and fit it permanently.

Now to get Parso ( hopefully ) to rid me of the excess bits hanging uselessly in my engine bay!

[Greg Roles]

Success! Completed a successful error free regen on the way to the airport with vagcom monitoring and closing the QTP flap about half. Yay!

[h100vw]

Sweet! 10 characters

[jazd]

So you have removed the EGR and made it possible to manually control the QTP flap?

What does the EGR do and what are the benefits of removing it? Likewise with manually controlling the QTP flap?