Project: RS2 ABY

[A80Avant]

there is also another 1 way valve, the black/yellow one going to the vaccum tree in case that is broken.

[Fat Audi 80]

Don't take this the wrong way Andy, but I can't help feeling something has been put back together wrong or is missing. I do hope you find the solution though as your car is going to be a monster!

[prj]

Make sure your fuel pressure is not too high as well.

[Ross]

Steve - as I've been banging on about in this thread, it felt to me there's a more serious issue than boost leaks. It's still niggling me that the breather system was getting pressurised when it's all blanked off on the intake side. Surely a cylinder should hold pressure at 0.7bar without leaking excessively. I wasn't sure but from others comments it sounds like there should be no valve overlap at all, which means if there is the timing is out.

Dmitri - fuel pressure is niggling me too. It would explain the fuelling issue. I wish I had swapped my FPR even though its' 3.8bar, just to check it. I actually think at this stage, the over-fuelling and boost issue are probably not related. Of course I could be wrong but I suspect if fuelling is sorted, it will probably still not make boost. Unless there is anything ECU wise that would pull back boost if it runs too rich?

[AndyP]

I had a similar issue on mine when it went for mapping. It turned out that the seals on the turbo were shot and boost was leaking into the CHRA and down the oil return line into the sump. Try unbolting the oil reurn line and testing again, you'll hear the air leaking out of the line if you have the same issue. This is how I found it on mine, but we used smoke, so it was really obvious what was happening.

[Billman]

Hi, I didn't read everything through but did you try to pressurize the system with the intake blocked at the throttle body? If you are pressurizing through the TB then air can escape also through the valves to the top cover and through overlapping to the EM. That way you will never see more than a certain amount or pressure because depending on the equipment you can not flow that much air at higher pressure.

[Lloyd]

Anywhere i can get this done before saturday?

http://www.perfect-touch.co.uk/

these guys did a leak down test on my car and I can recommend them.
Please ask them to torque the plugs to 30nm though, not BFT!

[Lloyd]

Don't take this the wrong way Andy, but I can't help feeling something has been put back together wrong or is missing. I do hope you find the solution though as your car is going to be a monster!

Hmmm, perhaps a dodgy gasket?

[Rusty]

It'll be something innocuous that's rather important and difficult to find or test...

Breather system pressurisation is a clue IMO. I'd blank it all off and run to atmopsphere to remove it from the equation - it's only the inlet plug and IM feed that need to be blocked and you'll be fine running to atmosphere for a few miles' testing.

[djh]

What fpr is fitted? stock or 7a

[dkw_dude]

Sorry if this has been mentioned but I'm too lazy to re-read it all.

dump valve? This sounds like it could be the only thing left.

Make sure that you fit a known working one and it's the correct way araound and has the pressure line to the top of it!

Other thing was the breather system connection to the N80 pipework (mentioned above). The 1-way valve is rather important, as it stops all your boost peeing out of the 8mm connection!

+1 on this. You can even remove dv and bung the connections for a test drive.

[Sonic]

I think FPR and WGFV are the next things to try... does anybody have a known-working 4 bar FPR or WGFV spare that i can try?

[prj]

Your PCV valve is probably shot.
The one that is a one way valve at the manifold... replace it.

Your intake MUST hold pressure.

[Jamo]

Sonic shouldn't have a PCV if he's running the catch tank setup from Rusty / JP

I haven't been through the whole thread but which catch tank setup are you running??

[Rusty]

It's not mine, it's based on JP's recommendation AFAIK - looks like a swirl and catch setup from the pictures and conversation I've had with Andy.

The problem area is the N80 & 1 way valve setup that attaches to the IM. If the vacuum to the IM is removed then you can ditch the PCV valve, if you want it all to work as stock, then it all needs to be designed to replicate the OE system, just with more volume and areas to catch the oil vapour and suspendd droplets.

For testing, I'd remove all links from the breather to the IM and inlet hose and vent it to atmosphere. When it's all sorted, you can then make sure all the connections are spot on.