Another EFR build

[viperdsa]

Figured I should start a build since I have been slacking on it.
Here is the planned build:

Motor
Motoza tuned
DM Forged Rods
Mahle Powerpack Pistons 83mm
ARP head studs, main studs, cam tower bolts, and crank bolt
Calico coated rod and main bearings
IE timing gear pin kit
Ferrea valvetrain
Twinscroll EFR 7163
Turbosmart wastegate
Mint Performance twinscroll manifold, downpipe, intake, compressor outlet and TB pipe
New OEM oil pump
CTS Turbo silicone intercooler hoses
AWE exhaust
Evolution Racewerks SMIC
S3 injectors
IE HPFP internals
155bar PRV
CTS Turbo throttle body spacer
Snow Performance w/m solenoid
AEM WMI
K&N Air Filter
Torqbyte PM4
JHM pick your pump kit
Walbro 450

Drivetrain
JHM stage 1 clutch and LWFW
USP metal slave cylinder w/ braided clutch line
JHM short throw shifter
034 motorsport street density motor mounts
Density line transmission mount

Suspension and Brakes
JHM 2 piece front rotors
Hawk HPS pads
Goodridge braided brake lines
H&R sport springs
Bilstein shocks
RS4 rear swaybar

Misc.
45mm Prosport oil pressure gauge
Draft42 oil pressure sender relocation kit
ECS 45mm vent pod
Newsouth steering column pod
Podi dual display boost/AFR gauge
Borg Warner turbo shaft speed sensor
Ebay defrost vent gauge pod
PTP EFR turbo blanket and Lava exhaust wrap

I'll get some pictures in here soon. Currently waiting on the w/m solenoid to stop her from siphoning and get her running a bit better. Have a short list of things that need fixing, leaking intercooler piping, leaking valve cover gasket, she's underboosting and not even hitting wastegate pressure and the water meth.

[viperdsa]

How she currently sits
IMG_20190421_192139737.jpeg

Sent from my moto g(6) using Audizine mobile app

[Operator]

Looking good! I'm sure it feels great to have everything coming together!

[canadianA4B7]

Another EFR happy to see!!

Not sure what boost your going for but I’ve had to replace all the IC clamps to keep the boost in. Some of those flat style clamps have not held in place against the boost.

[theguysinger]

Oh man, I love seeing these builds with EFR’s on them. Subbed for lots of boost :D

[viperdsa]

Took forever to get to this point and I'm just happy to have it back from the shops.

Not sure what's up with the boost it's only hitting 9psi, with a 14psi wastegate spring. The leak from the intercooler doesn't look nearly big enough for that kind of leakage. Through another mm of preload on the wastegate and was waiting for the solenoid before taking it back out and seeing if there was much of a change.

What kind of clamps did you go to Canadian?

Sent from my moto g(6) using Audizine mobile app

[viperdsa]

Got the solenoid installed today. Idles so much better. I'm gonna have her smoke tested then start pulling logs for Motoza and start getting her dialed in.

[al3k]

Nice build!
Do you have more pics of the exhaust manifold? Can I ask what you paid for it?

[viperdsa]

Nice build!
Do you have more pics of the exhaust manifold? Can I ask what you paid for it?

https://www.instagram.com/p/Bur1n4EnSyS/?hl=en

There are some more pictures. I think it was 1300 for the manifold.

Sent from my moto g(6) using Audizine mobile app

[viperdsa]

Replaced some gaskets and re routed the dv lines so it is just directly connected to the intake manifold and not the N249. Builds more boost but still only gets to 11psi. Ordered the same pressure tester i3oricua used and gonna see if I have any crazy boost leaks.

Sent from my moto g(6) using Audizine mobile app

[i3oricua]

Replaced some gaskets and re routed the dv lines so it is just directly connected to the intake manifold and not the N249. Builds more boost but still only gets to 11psi. Ordered the same pressure tester i3oricua used and gonna see if I have any crazy boost leaks.

Sent from my moto g(6) using Audizine mobile app

That boost leak tester will make things easier at home for sure. All you really need is a compressor of some sort. Glad to see someone else doing the EFR. My tuner kept trying to get me to go K04. I refuse and now will use a different tuner since he won't respect what I'm trying to do.

[viperdsa]

Disconnected the n75 from the wastegate just to see what it would do. It made all kinds of boost. So it would seem the n75 or something related is my problem.

Sent from my moto g(6) using Audizine mobile app

[i3oricua]

Disconnected the n75 from the wastegate just to see what it would do. It made all kinds of boost. So it would seem the n75 or something related is my problem.

Sent from my moto g(6) using Audizine mobile app

Did you get an overboost code? Could be you were just running off of wastegate pressure so it’s based on whatever spring you have in the wastegate. I guess I’m assuming you have an external wastegate. I’ll up have to scroll up. If that’s the case then it could be N75 or your tune or lack of. For once I’ll echo what Evolution would say and do some logging of your N75 and see what requested vs actual is.


Sent from my iPhone using Tapatalk

[EvolutionArmory]

Don’t these EFR turbos have what they call wastegate canisters? High, medium and low? Isn’t default medium?

Maybe a different one is necessary.

- - - Updated - - -

Did you get an overboost code? Could be you were just running off of wastegate pressure so it’s based on whatever spring you have in the wastegate. I guess I’m assuming you have an external wastegate. I’ll up have to scroll up. If that’s the case then it could be N75 or your tune or lack of. For once I’ll echo what Evolution would say and do some logging of your N75 and see what requested vs actual is.


Sent from my iPhone using Tapatalk

You should always echo what I would say. 😉

[viperdsa]

I'm using a single port Turbosmart IWG with a 14psi spring and i think 5mm of preload.

I logged it a few weeks back and if I recall correctly it was requesting 1.5bar. I have some codes to clear that were there prior to the wastegate experiment so we'll see what is there, and probably log it again with the n75 attached.

[EvolutionArmory]

I'm using a single port Turbosmart IWG with a 14psi spring and i think 5mm of preload.

I logged it a few weeks back and if I recall correctly it was requesting 1.5bar. I have some codes to clear that were there prior to the wastegate experiment so we'll see what is there, and probably log it again with the n75 attached.

Call your tuner and ask them what type of crack pressure the tune is expecting and set your wastegate up so it responds to what the software is expecting. Log your N75 duty cycle and adjust it if necessary. If you’re getting high N75 duty cycle you might want to add some more pretension. Do a log of 003, 115 and 119

[viperdsa]

Pulled codes and they are the same two that I have been getting P2188 and P0507.

[Charles.waite]

Call your tuner and ask them what type of crack pressure the tune is expecting and set your wastegate up so it responds to what the software is expecting. Log your N75 duty cycle and adjust it if necessary. If you’re getting high N75 duty cycle you might want to add some more pretension. Do a log of 003, 115 and 119

Its Motoza's BT tune, so its a pretty custom job Dave probably specs out based on the equipment. I doubt viper pulling logs is going to help a ton, he should focus on eliminating leaks and making sure the N75 is functioning properly.

OP - That manifold is beautiful. Was just perusing their Instagram, thats some phenomenal welding!

[i3oricua]

Pulled codes and they are the same two that I have been getting P2188 and P0507.

Sounds like you have a vacuum leak somewhere but the confusing thing is that your getting a rich condition code and not a p0171 which is a lean condition code. I’m pretty positive you have a vacuum leak but I’m not sure if that will make both your codes go away. That leak tester should be helpful when it arrives.


Sent from my iPhone using Tapatalk

[canadianA4B7]

Are you using the boost prv on the turbo compressor manifold?

And did you purchase the high boost PRV spring for it (20 psi +) if not I likely am the only one that can ship this out ASAP it too Borg Warner 6 months to get this out the door so I ordered 2 in case this happens to someone else.

[EvolutionArmory]

Its Motoza's BT tune, so its a pretty custom job Dave probably specs out based on the equipment. I doubt viper pulling logs is going to help a ton, he should focus on eliminating leaks and making sure the N75 is functioning properly.

OP - That manifold is beautiful. Was just perusing their Instagram, thats some phenomenal welding!

Custom tune = pulling logs helping a ton. Especially when trying to see if the N75 is working properly. I’m assuming this is a base file that is expecting certain parameters and are tweaked from there. Getting in touch with Motoza and finding more info about what the base tune is expecting seems like the best way to go.

Wastegate crack pressure/pre tension was a huge obstacle for me when it was set to HALF of what it should have been from the manufacturer and it took me forever to figure out that it was set wrong, and that was with only a K04. Pretty standard set up. It would seem a simple phone call could set that straight. Especially since these EFR turbos have pretty customizable wastegate set ups. It’s not like a K04 where 8-10 psi of crack pressure is pretty standard. There is no real standard with EFR’s since they have a low, medium or high wastegate canister available.

Could the fuel trim codes be caused by a faulty throttle body? It might not be a bad idea to check block 60 at idle and make sure throttle position and valve position equal 100% when added together. I’d try a TB alignment too.

[viperdsa]

Canadian: I did not get the high boost prv spring. I swapped the stock prv with a turbosmart kompact plumb back valve. When I disconnected the wastegate from the n75 it held 20+psi fine.

Pulled a log using Motoza's program so it has pre-determined things it pulls. N75 duty cycle was around 40%. Boost actual vs boost requested we're interesting. It was requesting 2.2bar and said actual was 1.8bar. While my boost gauge was reading 11psi. Wondering if my MAP sensor might be on it's way out.

I'll try the throttle body alignment because there was a lot of hassle getting the water meth plate to seal. Going to send in the little log I did to Motoza's on Thursday and see what they think.

Pressure tester gets here Thursday. I know I have a pin hole in one of the fabbed intercooler pipes, but I don't think that is big enough to cause these issues.

Sent from my moto g(6) using Audizine mobile app

[Charles.waite]

My guess is a bad sensor or possibly a bad ground somewhere in the bay. I'd give the grounds a double check for tightness just to eliminate that common and stupid goof people make reattaching stuff in the engine bay when they're moving too quickly.

[i3oricua]

Canadian: I did not get the high boost prv spring. I swapped the stock prv with a turbosmart kompact plumb back valve. When I disconnected the wastegate from the n75 it held 20+psi fine.

Pulled a log using Motoza's program so it has pre-determined things it pulls. N75 duty cycle was around 40%. Boost actual vs boost requested we're interesting. It was requesting 2.2bar and said actual was 1.8bar. While my boost gauge was reading 11psi. Wondering if my MAP sensor might be on it's way out.

I'll try the throttle body alignment because there was a lot of hassle getting the water meth plate to seal. Going to send in the little log I did to Motoza's on Thursday and see what they think.

Pressure tester gets here Thursday. I know I have a pin hole in one of the fabbed intercooler pipes, but I don't think that is big enough to cause these issues.

Sent from my moto g(6) using Audizine mobile app

That spot that you’re talking about with the meth plate and the throttle body is exactly how I kept getting my p0507 code. I had a pretty large leak on one corner but it also caused a really rough idle. Those threads for the intake manifold where the throttle body connects strip very easy.


Sent from my iPhone using Tapatalk

[EvolutionArmory]

You usually need to subtract atmospheric pressure from your log to really see what boost pressure really is. So your actual boost of 1.8 bar (26 PSI) is actually 11.3 psi if you subtract atmosphere (14.7 psi).

So your tune is really asking for 17.2 PSI but actual is really 11.3. I’d adjust your wastegate a little more and see what happens if you aren’t bleeding boost at your throttle plate.

And all of that needs to be done after you do a boost leak test and seal any leaks you do find.

Just spit balling.

[viperdsa]

That spot that you’re talking about with the meth plate and the throttle body is exactly how I kept getting my p0507 code. I had a pretty large leak on one corner but it also caused a really rough idle. Those threads for the intake manifold where the throttle body connects strip very easy.


Sent from my iPhone using Tapatalk

Yeah, I have a feeling I probably have a leak there. The shop that did the water meth install couldn't get the IE water meth plate to seal with 3 different gaskets. So I got the CTS plate which uses an o-ring and they said that they were able to get that one to pass a smoke test. Guess I'll find out Thursday.

Sent from my moto g(6) using Audizine mobile app

[viperdsa]

You usually need to subtract atmospheric pressure from your log to really see what boost pressure really is. So your actual boost of 1.8 bar (26 PSI) is actually 11.3 psi if you subtract atmosphere (14.7 psi).

So your tune is really asking for 17.2 PSI but actual is really 11.3. I’d adjust your wastegate a little more and see what happens if you aren’t bleeding boost at your throttle plate.

And all of that needs to be done after you do a boost leak test and seal any leaks you do find.

Just spit balling.

Completely forgot you need to pull atmospheric pressure.

Sent from my moto g(6) using Audizine mobile app

[i3oricua]

Yeah, I have a feeling I probably have a leak there. The shop that did the water meth install couldn't get the IE water meth plate to seal with 3 different gaskets. So I got the CTS plate which uses an o-ring and they said that they were able to get that one to pass a smoke test. Guess I'll find out Thursday.

Sent from my moto g(6) using Audizine mobile app

What I do for that specific section is I helicoil the threads and it seals amazingly well. I recommend doing this or you may never get that area to seal which i suspect you have a leak from.

I don’t know if your boost is holding well but what I would guess is probably happening is that you hit peak boost right away and it falls off really fast because of that leak. Just a theory. You might have other problems as others have listed here.


Sent from my iPhone using Tapatalk

[EvolutionArmory]

Hey, when you said your duty cycle was 40%, for how long was it 40%? If your duty cycle starts out really high, drops really low and climbs right back up again 2 things are most likely happening. You have a good sized boost leak and your car is throwing more boost at it to try to compensate making the duty cycle high at high rpms or your wastegate is set up wrong and it’s not staying shut long enough during ramp up.

Here’s my worst N75 log when I was figuring out my issue.

Hit 35% at the low, was in the 50’s and 60’s for a bit but climbed up to 90 at the end.


Here’s a better one that stays in the 60’s for most but spikes at the very end. This is pretty acceptable

[viperdsa]

I'd have to go log a full pull and pay attention to it. The pull I'm thinking of was only 3-4k in 4th, and it didn't move anywhere.

Sent from my moto g(6) using Audizine mobile app

[EvolutionArmory]

Gotta log the whole rpm range. 4th Gear is a go to jail instantly log at redline. Try 3rd🤣🤣 That’s like 90-100. Just a big ticket.

[viperdsa]

Lol yeah. Gotta pressure test it Thursday, pull some decent logs for Motoza and Friday it goes in to get the intercooler pipe fixed.

Sent from my moto g(6) using Audizine mobile app

[seal66]

Good to see another build. I am curious but since you used motoza and mint you must be here in Denver?

Sent from my SM-G955U using Tapatalk

[viperdsa]

Not quite Denver but close enough

Sent from my moto g(6) using Audizine mobile app

[seal66]

Where you located at? I have been wanting to do an early but wanted to see how it acts up here


Sent from my SM-G955U using Tapatalk

[viperdsa]

Little south of Denver. My car as it is now wouldn't be the best representation of how an EFR will be up here. Between my boost leak and the fact that it is still on the base file I was sent, and have not had any revisions done yet.

[viperdsa]

Well evidently my pinhole in my intercooler pipe is bigger than I though. Could barely get the system to pressurize to check for leaks. That hole gets fixed tomorrow then the search for more leaks continues.

[viperdsa]

Got the intercooler pipe fixed today. Pressure tested the system and the only two things I heard was what sounded like a leak if I put my ear to the valve cover; and the sound of oil bubbling. The PCV was good, tried the new one that I got from Audi last week and it leaked, so went back to the one that was on the car.

Went and pulled a log. Thought I blew a coupler during a 3rd gear pull, but didn't see anything disconnected or torn hose so I think it was limp mode. Didn't throw a CEL, gonna go for a drive later to see if it is the same and if I need to go search more thoroughly.

Even with the pipe fixed still only making 10psi of boost so gonna send the logs to Motoza and see what they say.

[EvolutionArmory]

Here’s a tip on boost leak testing. Remove the PCV hose from the intake manifold and make a cap for it. I used an old PCV hose, took the hose section off and put a rubber plug on the end of the connector. The perfect cap for the job. Then you won’t have your cylinder head pressurized. Just your intake.

[EvolutionArmory]

Once you make absolutely sure your intake is leak free, do a Log of 003, 115 and 119. If your boost looks like this and your duty cycle is through the roof, you probably need to do some wastegate tweaking.



This was with my wastegate set 4 psi lower than it should be. It wasn’t staying shut long enough to build boost so it was bleeding it off and not reaching full spool til 4K and dropping off real fast. This is only a K04.

With the right wastegate settings I’m now hitting 25 PSI before 3K and holding 20 til 6K before it tapers.