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Mk5 General Area / Re: Cambelt Change
« Last post by Jons1001 on May 11, 2024, 02:50:47 pm »
Just to update I rang tps and they said the price for the timing belt was £212 plus Vat and then other £68 plus Vat for the waterpump  :surprised:

VW main dealer on ebay said they can do the whole kit for £250 Inc Vat.
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Yeah I wouldn't go past 1.6 bar personally. The journal bearings don't like it and it's starting to surge out of its efficiency zone at that pressure ratio, but should be OK if you do regular oil changes and have a better intercooler. 

I found 1.5 bar to be the sweet spot for the power to lifespan compromise.  Stock S3s ran 1.2 bar for 265hp, so there's not a massive amount of headroom. Borg Warner quote a sustainable 300hp max for the K04 but they're capable of more in short bursts. Poor tuning can crack them around the wastegate as bad tuners they don't control the EGTs properly, or turn off component protection completely.  I've seen a complete fracture of the entire housing as a result of that.

Is your throttle body a VDO one? If so, I would swap it for the newer Continental one. I had surging and throttle valve flutter issues with the gen 1 VDO throttle after it was tuned.

How many grams/sec at idle are you seeing?  Normally around 2.5 - 3 g/s at hot idle.  When my MAFs used to go, it would dip below 2 at cut out.  Surging from the turbo used to fling PCV oil up into the turbo intake pipe and soak the MAF. It's a really poor location.  VW moved it much further away from the turbo on MK6s onwards for that reason.

VW just close the injectors on overrun and open them again around 1200rpm to give the idle control map time to kick in. The HPFP being mechanical will still be making pressure.

Need to be careful with the rail pressure drops as 25% lambda is the maximum compensation.  Below 80-90 bar it runs out of options, retards the ignition (which also has an adjustment limit) and then it detonates because it's too lean.

You definitely need pump internals, and maybe the RS4 pressure relief valve as well as the stock one cracks open at 128ish bar.

I never had any problems with a Revision D, but there are some silly myths about them being 'designed to leak', which is nonsense.  My DV+ failed. The rubber pad unglued itself and fell off.  Really poor design.















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Mk5 General Area / Re: Stage 2+ K04 Conversion Burning Oil
« Last post by pudding on May 11, 2024, 12:25:23 pm »
My ED30 didn't use anything between 3-4000 oil changes, so something isn't right there.

White crusties on the spark plugs - the engine is burning it. Clean plugs - it's leaking past the turbine shaft seal.

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Mk5 General Area / Re: WTF!! Has my car been mapped?? :|
« Last post by ZoliWorks on May 11, 2024, 12:06:31 am »
With VCDS, look at boost specified, boost actual, intake air mass g/s and actual torque. You can use intake air mass and torque to estimate BHP. Take the car for a pull in 3rd gear from 3k to 5.5-6k and you should get a good enough reading. Or if you can do the same in 4th gear, it's even better.

My cracked k03 turbo, on a stage 2 map, was underboosting by 0.3-0.4 bars throughout the powerband and making somewhere between 220-230hp
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Mk5 General Area / Re: WTF!! Has my car been mapped?? :|
« Last post by Reeceyy on May 10, 2024, 11:06:18 pm »
Yeah my turbos got a crack in it too! What bhp you reckon it could be running??
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Mk5 General Area / Re: Stage 2+ K04 Conversion Burning Oil
« Last post by GVK on May 10, 2024, 10:56:04 pm »
How much we talking ? I seem to remember reading that VW state TFSI can use up to 1 litre every 1000km (621miles)
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Mk5 General Area / Stage 2+ K04 Conversion Burning Oil
« Last post by K03MK5 on May 10, 2024, 10:14:16 pm »
Hi all. Recently completed the K04 build and loving it.  Only thing I've notice is its burning oil like there is no tommorow.  Normal????
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Mk5 General Area / Re: WTF!! Has my car been mapped?? :|
« Last post by ZoliWorks on May 10, 2024, 10:07:19 pm »
Your car is stage 1/2 mapped. With a stock tune, there's close to no wheelspin. With a stage 1 tune AND a broken turbo, I was spinning all the way in 2nd gear. I could come off throttle then floor it again and it would spin again.
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Mk5 General Area / Re: Milltek vs Pipewerx
« Last post by ZoliWorks on May 10, 2024, 10:04:52 pm »
Yeah that's the one. Tho it's funny. The rest of the exhaust on the Jetta is stock while the downpipe is custom all the way back to under the rear seats where it's connected to the exhaust. On the golf the whole system is stock, minus the cat, which is a sports cat.
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Yeah it's definitely more punchy, that's fur sure. It has power past 6k and pulls throughout the powerband (2nd and 3rd gear). I don't regret the swap one bit. It sounds way better but that might just be because it's pushing 1.6 bar pressure almost all the time.
The throttle body was cleaned and tested, moves nicely. The MAF doesn't show any signs of being worn out just yet.

Now, regarding the loss of power and the leak. There is no leak. The map the car had demanded way too much fuel pressure and my fueling system can't keep up. We've changed the map so the car no longer stalls when coming off throttle or clutching in. It also drives a bit better but it still cuts out all the time past 5k in 4th gear or above. The map is still demanding 130 bar pressure sometimes and the stock fueling system fails to make that. I've seen it drop all the way down to 67 bar even and the idle pressure is 50!!!
Now the reason the car was stalling or idling rough when coming off throttle is because the ECU is still demanding the same fuel pressure off-throttle. Why VW did this? I don't know. What I do know is that if the fueling system can keep up, the car idles fine and doesn't stall.

Since there are no issues to speak of really, I've decided to keep it like this rather than restrict power as I rarely ever need to rev past 5k. With my daily commute being mostly city driving, I'm fine for a while. If there were no fuel cuts, the car would make between 290 and 300hp according to the tuner. It's definitely putting down power now, no questions asked, just not past 5k.


Next step, sometimes in the coming months, because I've spent way too much this past months, is upgraded fuel pump internals and a stronger fuel rail pressure valve.

TLDR: Car loses power past 5k rpm not because of vacuum leak but because of fuel cuts.


Side note
I've been switching between the DV+ and the revision D valves. Both can hold pressure equally well but the DV+ makes it sound like a supra when coming off throttle because it can't let out pressure fast enough. My mechanic/tuner said this isnt all that bad for the turbo, but the ECU doesn't like it one bit. It's constantly throwing "pressure release valve mechanical failure" errors. The rev D is fine but sounds average, as expected. I've switched back to the D for now but if I want to show off the car, I'm putting the DV+ on. It's a 2 minute job anyway since the relocation kit brings the valve to the front of the engine, right next to the throttle body.
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