B3 Audi 80 16V Sport (1.8 Turbo) - loads of pics

[1781cc]

Long time with no updates, purely because of issues affecting how the car has been running - as you will probably realise if you have been following this thread is that the last installment had me crestfallen after a dyno run producing 0.5 bar of boost and minimal power.

Well, 3 people have looked at it so far and Martin over at Marlin Motor Engineers in Bletchley managed to trace all the faults and chuck it on the dyno to record a healthy 170.6 bhp and 251.1 nm of torques :arf:

Problems:
- no comms with ECU as diagnostic line wasn't connected properly
- missing barometric pressure sensor
- missing purge valve
- coolant sensor circuit had a nice clean cut in it from a stanley knife

but its all running fine now, aside from a few gauges reading the wrong things (engine temp and oil pressure are pinned to the max at all times and the oil temp doesnt register) - needless to say, minor issues as I know everything is good in VCDS and will get that looked into at a later date.

1.0 bar of boooooost

Onwards and upwards, faith restored and watch this space for more improvements.

BTW: Car pulls like a train compared to before and I smoked a 328 Bimmer on the way home! 'ave it...

[1781cc]

oh, and ChrisAudi80 and Acidburn - at the moment the inlet hose is off and the cone is sitting straight in the engine, a cold feed and rework of angles is on the list of things to do with the AEB

:-)

[AndyP]

Try swapping the wires on the oil pressure sensor, having them the wrong way round will make it read maximum

[sam80quattro]

Just noticed its only making power until 5.5k rpm? Bikerjim uses a golf mk3 gti temp sender to make the gauge work.. I was happy with 120degrees lol I've only just sorted my oil pressure light coming on the autocheck. I originally used the pressure gauge sender and the aeb oil light switch and its the switch that's the issue as they work at different pressures... Get a t28 bolted too it and go chasing new shape m3s lol

[ChrisAudi80]

Thanks for updating. Was wondering what was happening. That 170hp and 251Nm is not bad, but 1 bar of boost should net you a little more.
You should be able to hit near 200hp crank and about 280Nm at 1.2bar, IIRC.

[1781cc]

Thanks AndyP - thats a good tip and so obvious I didnt think about it!

ChrisAudi80 - I think that the "Stage 1" map Aidan had previously tried to load on the car hadn't taken because of the intermittent communication with the ECU, so I will take the car back to him and get him to reload the map on to see what happens. I think the power it is making now is stock, plug improved cooling/exhaust/air based on non-standard part mods. I will update this post map

Sam80quattro - The dyno goes up higher, but the power props off after that because of the K03 rev-range, this was more of an exploratory run rather than a set of full runs to chase power. The key was getting the car to boost right and then work on improvements, other issues.

Good to know about the Golf GTi temp sender and also the pointer about the oil pressure - what switch did you end up using to solve this? mine only errors when the stereo is turned on before I start the engine (!)

[sam80quattro]

I used a cream/white switch off a 10v as that what engine was in mine.. How high does the rev counter go in the car? Minesometimes goes all the way to 6800 ish before hitting the limited but normally it only shows 5250 on the clocks lol for the oil temp and pressure gauge.. Try swapping the words between the 2 as without the temp gauge plugged in mine stays at the bottom so maybe there mixed up.

[1781cc]

hmmm, I will look into the wires swapping round, its odd because the gauge worked fine before, will trace and switch.

So regarding the pressure switch, does that mean I need the AEB one or one off the original ACE engine?

Sorry for all the questions but I appreciate your help!

[sam80quattro]

Use the ace 1..

[Greg_S]

Glad you tracked down the problems, looks like most of them were relatively simple on their own but a pain together. Hopefully see it over in MK on Wed

[1781cc]

Yeah man loads to moving forward but its good to know where things have been going wrong and gives me some focus for the future!

Not going to be there Wednesday, working in Philadelphia but maybe next or towcester buddies?

[1781cc]

Custom Exhaust by MIJ

OK, the previous exhaust system was a bas****isation of an S2 coupe, the 80 and the passat - needless to say, Aidan did his best but it wasn't exactly as freeflowing or as pretty as it needed to be. Once we solved the boost issue, I could start to move ahead with tuning and improving things.

I had done my research on MIJ Exhaust in Walsall (www.mijexhaust.com) and had high expectations - I have to say that they delivered and more!

The brief was to remove the existing Frankenzaust and have carte blanche to create something that didn't clatter about all over the place and take advantage of their lifetime warranty, afterall, the car has done 22 years already and I want more out of her yet.

Old System:





The main problem I had wasn't their fault and will need to be tackled moving forward: The oil filter had been knocking on the subframe and punctured a whole in it, which mean it would piss oil out while running, but because the oil would settle when stationery, there were no leaks on the driveway, its something that shouldnt have happened in the first place, this problem is further compounded by no oil warning lights being lit up when I had about a quarter of oil in the engine.

Thankfully no damage, a new flush of oil and filter (which will still knock till I find a shorter one in halfords tomorrow)

Back to the exhaust, the system was built meticulously piece by piece and tacked together as they went in order to check fitment and alignment.

Removed:


New System going in:






Their attention to detail was amazing and the result is a system that I am very happy with, both from a build quality point of view and also sonically.

Walkthrough video:

http://www.youtube.com/embed/iavcjah-ZcQ

Not too loud, no drone, almost OEM but the sound opens up loads and becomes really sporty under load over 4K rpm.

This is the view most people will have:


Too late to record a video last night, but will pop one up first thing I can.

[quattrostyle]

looking very good

[m4xmw]

Great project, and full credit to you for ironing out the problems as you go.

I take it you need a smaller oil filter to give you more clearance?

what sort of money did MIJ charge for the exhaust, it looks very neat and well put together?

Keep the updates coming too!

[TimE-J]

Exhaust looks great, certainly looks like they did a good job!