Well it looks like I’ve finally got the breather system sorted out. After the car was mapped I found I was getting large amounts of oil in the inlet pipework so I decided to upgrade to a swirl pot and catch tank
I got the swirl pot from Andy Casey ( thanks again Andy
) and I was intending to swap to an ABY fuel rail so I could bolt the swirl pot to the earth points on the inlet manifold. This didn’t work as the FPR hits the manifold, likewise I couldn’t fit the ABY manifold because it hit the distributor.
So I ended up ditching the carbon canister and fitting both swirl pot and catch tank behind the fan. The layout is based on this design that JP posted
The only difference is that Andy’s swirl pot uses a 30mm hose from the ‘darleks head’ on the side of the block. I also changed the fitting on the back of the cam cover to a 16mm pipe and added an internal baffle to stop it dragging oil into the system under hard acceleration. I’ve only done about 35miles today and so far the inlet is staying dry.
Now onto the performance, so far this is disappointing to say the least
. Because of the issues with the compression ratio being too high and the possibility that the knock sensors were not going to work on the TDi block it was decided to keep boost to around 1.5bar. We fitted a 1.5bar spring and back the preload adjuster all the way out, which give 1.4bar. The problem is with the way the turbo builds boost, from 2000rpm on WOT it starts at about 0.8bar then at 3000rpm it’s up to 1.0bar which it hold until 5000rpm when it jumps to 1.4bar. Between 5 and 7000rpm it holds 1.4bar and to be fair, is quite quick, although my butt dyno says it’s only low 300’s.
The whole point of going for the stroker engine with a relatively small turbo was to get an early spool and a really strong mid range and this is the opposite of what I’ve got. The map is set to be safe so it’s running a rich and has very little timing but I don’t think this would affect the boost delivery, I suspect there may still be a problem with the turbo. I've been reading Ross's thread when he put a 3071 on his old coupe and he was getting 1.5bar @ 3000rpm, and that was on a 2.2 with std head. The only difference was he had the 0.63A/R hot side and I've got the 0.82A/R, how much difference would that make? Not the 2000rpm I'm see I suspect.
I’ll be at MRC next Saturday so it will be available for test rides and hopefully somebody can point me in the right direction as to what’s wrong with it.
I got the swirl pot from Andy Casey ( thanks again Andy
) and I was intending to swap to an ABY fuel rail so I could bolt the swirl pot to the earth points on the inlet manifold. This didn’t work as the FPR hits the manifold, likewise I couldn’t fit the ABY manifold because it hit the distributor.So I ended up ditching the carbon canister and fitting both swirl pot and catch tank behind the fan. The layout is based on this design that JP posted
The only difference is that Andy’s swirl pot uses a 30mm hose from the ‘darleks head’ on the side of the block. I also changed the fitting on the back of the cam cover to a 16mm pipe and added an internal baffle to stop it dragging oil into the system under hard acceleration. I’ve only done about 35miles today and so far the inlet is staying dry.
Now onto the performance, so far this is disappointing to say the least
. Because of the issues with the compression ratio being too high and the possibility that the knock sensors were not going to work on the TDi block it was decided to keep boost to around 1.5bar. We fitted a 1.5bar spring and back the preload adjuster all the way out, which give 1.4bar. The problem is with the way the turbo builds boost, from 2000rpm on WOT it starts at about 0.8bar then at 3000rpm it’s up to 1.0bar which it hold until 5000rpm when it jumps to 1.4bar. Between 5 and 7000rpm it holds 1.4bar and to be fair, is quite quick, although my butt dyno says it’s only low 300’s.The whole point of going for the stroker engine with a relatively small turbo was to get an early spool and a really strong mid range and this is the opposite of what I’ve got. The map is set to be safe so it’s running a rich and has very little timing but I don’t think this would affect the boost delivery, I suspect there may still be a problem with the turbo. I've been reading Ross's thread when he put a 3071 on his old coupe and he was getting 1.5bar @ 3000rpm, and that was on a 2.2 with std head. The only difference was he had the 0.63A/R hot side and I've got the 0.82A/R, how much difference would that make? Not the 2000rpm I'm see I suspect.
I’ll be at MRC next Saturday so it will be available for test rides and hopefully somebody can point me in the right direction as to what’s wrong with it.
mine was running 1.7 bar which gave a real good kick as you know ,surely it's the map that is making it boost later on ,mine ran very differently when using different chips/maps from steady to aggressive on the Mtm one ,the first one needed revs before it did anything if you remember ,hope you sort her after all the effort 
or swap it for a ko4ed S4 
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