Roni - TFSI Maxi

[VeeDub]

My new-to-me Caddy Maxi named Veronika (Roni for short).




Ex British Gas which originally was a 1.6TDI manual, now converted by Overboost to an EA113 2.0TFSI and 6 speed DSG.

It’s running a KO4 turbo and has some kind of tune - I can’t confirm the power. On VCDS it says it’s an LM Tuning Stage 2 map but no idea what that actually equates to. I have a feeling it’s missing a couple bits to make the most out of the KO4 and certainly doesn’t feel like a 300BHP van as it stands.

Alongside the engine conversion, its had a MK7.5 GTI hybrid bumper, Stance coil overs, Bola 19” wheels on the outside. Inside it has a Touran dash and 5 Touran seats. Upgraded multi-functional steering wheel and a fair amount of carpeting and Alcantara.

I was looking for a van I could take the mountain bike away camping for the weekend, fit a motorbike in, daily and still fit in a parking space / multi-story. Having owned a long wheel base Sprinter van before this, going back to a small and fast van has been soooo good.

In the last month I’ve stripped out the back to sound deadened and thermal line it. The reverse camera fixed with a proper relay set-up. New lambda sensor, both thermostats, a CV boot and chasing a couple air leaks. Weirdly the van didn’t have a diverter valve (recirc or vent-to-atmosphere) so I’ve fitted the standard KO4 set-up with a rev G DV.

It’s in need of some paintwork fixes include a dent or two and I’ve got some finishing touches to spruce up the interior a little. Then I’ll get it booked in RTech for a proper KO4 tune.

Literally just come back from a 1600mile trip to the Italian alps - she did great!


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[Doc]

Cool looking Caddy, will be good with the problems fixed and a decent tune on it.
That's a decent road trip you've taken it on too, real shake down.

[VeeDub]

Been long putting off a gearbox leak but I finally tackled it.

The output driveshaft seal has been weeping so today I got the drive shaft and flange out and changed the seal. Good time to also service the gearbox with new fluid and a filter.

Old seal out


Oil dirty seal



Was mildly terrifying getting the oil level correct and the first test drive but we’re all good!


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[VeeDub]

Next up on the list - cam chain casing was leaking oil.

Whilst I was there I planned to change the chain and tensioner to which all was going well until the bolt holding the cam sprocket stripped



Not ideal but the seals have been replaced dso hopefully no more oil leaks. New spark plugs in at the same time.



The high pressure fuel pump died so I’m waiting for a replacement before I can fire her back up again


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[Doc]

The bolt for the cam sprocket is high tensile 10.9, they don't strip easily. Are you sure you were using the correct tool?
It's a M8 Ribe, not a common tool and not something everyone has.

[VeeDub]

Hey Doc

I was surprised and pretty annoyed about it.

Yeah I bought a genuine VW tool for it as I’d read about other versions snapping.

I think someone had been here before me so perhaps that didn’t help.

I had a 900mm breaker bar on it and it wouldn’t budge - it was dam tight!


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[Doc]

Yep, it looks like someone has beaten a spline bit in there at some point.
They do get tight but should never be so tight that a 900mm breaker bar won't shift it.

[VeeDub]

New high pressure fuel pump turned up and the engine is back running again! I find it odd for the mechanical pump to completely let go and out of curiosity I'll be giving it a post-mortem.

Anywho, first test drive and the low oil pressure warning came up. If you know the EA113 engines, this is a common problem

Whilst I was doing the cam chain I replaced the little seals on the cam adjuster which controls the variable valve timing and at the time I was overly sure about them. They're little plastic rings which help with controlling oil flow and now I'm wondering if these could be the reason for the low oil pressure...

First step is to buy a mechanical oil gauge and see what the oil pressure is doing... (thats what I'm telling myself as my impulse is to burn the van and claim on the insurance )

[VeeDub]

After much worrying, the oil pressure issue was very obvious as soon as I dropped the sump





Oil pick up pipe was absolutely rammed with sealant. Who ever last had the sump off used way too much sealant

Cleaned it all out and now the oil pressure is back to where it should be. Phew!

It now looks like my in-tank fuel pump is dying as I have an intermittent issue with it and loosing fuel rail pressure… it’s never ending!


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[VeeDub]

Been over a year here’s some more updates:

Had fuel pressure issues and thought it was related to the LPFP. So I bought a new pump, one from a Golf (the donor car) as it’s now petrol only to find this was incorrect. You can see the differences below. It took me a while to figure out how a petrol pump fits into a Caddy diesel tank - it’s the top half of the Caddy bolted to the bottom half of the Golf pump!



Anywho, a whole load of faff later and it still didn’t fix the problem. I was at a bit of a loss and as a punt changed the return line off the HPFP as I knew the end was a little frayed. Amazingly this fixed the problem, it was delaminating so must have been collapsing when the HPFP was drawing in fuel.



Rear brake discs and pads got replaced as some numpty fitted the wrong size discs. Old ones in front and new ones behind



Some rattles were also fixed for the MOT, new lower ball joints, top mounts and rear shocks - the quiet bliss of being rattle free!! Finding the correct rear shocks for a lower Maxi was a little tricky but eventually settled on some Koni shocks and they’ve been great!



It flew through the MOT with no advisories. Think the MOT man was blind but hey I’ll take that!

New air con condenser got the aircon working over summer which has been amazing, although the fans don’t seem to be kicking in so it doesn’t work when stationary - that’ll be on the list to investigate before next summer!

It’s had some new Goodyear Eagle F1 Asym 6 tyres on the front and is going to R-Tech next week to have a bunch of work done. Mainly inlet clean and injector testing ready for its map. Hoping for around 350BHP when it’s done!!


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[Baldspeed Racing]

wow that oil pick up pipe well saved there. Nice build also btw

[VeeDub]

wow that oil pick up pipe well saved there. Nice build also btw

Cheers!

That oil pick up pipe was a shocker! I used the smallest amount of sealant possible when refitting the sump

[VeeDub]

Well the van is at R-Tech for some tuning goodness and general health checking!




Step one was to drop the turbo out and change the waste gate. It had a Forge one fitted which R-Tech advised would be a PITA to tune with so we agreed to fit a known entity supplied by them.



When I bought the van it was rumoured to have an anti-surge core but couldn’t confirm so this was checked at the same time. Super chuffed to hear the rumours are true!



Next steps are inlet off, check which injectors I have and give the inlet valves a clean. Then a new fuel pressure valve, fuel rail pressure sensor and MAP sensor before it goes on the dyno! Can’t wait to get her back!!!


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[VeeDub]

She’s back from R-Tech!!

Turns out the standard injectors were fitted so they got upgraded to the larger KO4 ones. Also had a new PCV, MAP sensor, Fuel rail pressure sensor and Fuel pressure relief valve whilst it was all apart.




On the rolling road my poor little BWA did 354BHP and 367ftlbs! Boost is lower in first and second gear to manage traction and it has 3 switchable maps (low, medium and high boost).







A lot of fun to drive, impressively manageable power and it certainly gets down the road!


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[Baldspeed Racing]

nice, bet shes well fruity to drive now then.