Any vw technicians on here????

[Ryanforsyth91]

Hi I've got a 1.4 tsi 160 which had a load of the usual misfire problems when it was owned by the previous owner. Anyway in the end it had a replacement engine and it's had no problems since. All I wanted to know was when be replace the engine do they replace it with an upgraded engine to prevent it happening again or is it a straight swap for the same engine? Also would a new engine come with the revised injectors and plugs etc or should I be checking to see if I need them? Thanks

[blower]

I'm not an actual VW technicians but i know their operating procedures...

The engine would have been the latest revision at the time, but would have been the same engine code - CAVD. So if replaced in 2012 it would have had the last revision of the CAVD engine in it.
Usually it would be the base engine only that is replaced - that's a full engine base (crankcase as well as cylinder head) - but no ancillaries whatsoever...although this does come with a whole new timing chain section - including tensioner, chain, camshaft adjuster etc

Unless they suspected a problem with them they would have used the existing injectors (changed the seals), sparks - although would have changed them if they looked warn / older part, ignition coils, intake manifold, boost piping, super charger, turbo charger, alternator etc

[Ryanforsyth91]

Thanks for the reply blower was changed just over 12 months ago. Car was registered in 2010 so I'm guessing it was one of the fault batch? Do u know if the latest revision still has problem or have they revised the Pistons and rings etc? Seems crazy how they would do all that work and not change the possible cause of the engine failure i.e injectors. I suppose that's how main dealer warranty works ( I work for one ) suppose I better check some part number can't be dealing with an engine going in the future.

[blower]

With it being just 12 months ago it would have been the last revision of the CAVD, and would have had the latest pistons & rings.

You might be able to check with VW if new injectors were fitted - if they did they would have ordered them and put it in with the warranty paperwork.
Getting to them to physically check is a PITA on this engine with many hours of disassembly...plus if you remove them you have to change the teflon seal (requiring a special toolkit)

Sparks are easy enough to check though - part no. 03C905601B being the latest.

In terms of other revised parts - the high pressure fuel pump was upgraded, but its not essential to change that, only if you are looking to push for stage 2 remap.
The ignition coils were also revised - but again its not essential to change those.

[Ryanforsyth91]

Thanks again for the reply mate very appreciated. I'll check with vw and see what they say. I'll also check plugs and coil part numbers. Am I right in saying the plug gap for cav engine has been revised to 0.7? Not planning on going stage 2 might map to stage 1 in the future but want to see people running a stage 1 for a while before I'm convinced aha. Also do u know if they use duel mass flywheels on the 6 speed manuals?

[blower]

CAVD, CAVE and CTHD are now 0.8mm gap officially - but new plugs are usually at 0.7 to 0.75mm actual to allow for gap increase over time.

I'm pretty sure its a single mass flywheel on the 6 speed manual, looking a pictures of it - it looks like a single mass to me. Flywheel failure is uncommon on these engines - I've never heard of one failing.

If you do go stage 1 - stick with revo. Even though the APR map is a lot more powerful in the mid range, due to a lot more torque - I really do not like their map, it runs the turbo in uncontrolled boost for most of the rev range and also runs way too rich on the AFR at around 4000rpm, causing misfires.

[Ryanforsyth91]

Thanks for that mate you've been a massive help. Ye heard the Apr maps run way too lean. Not good combination with an engine that already runs somewhat rich already. What sort of bhp are u running at the minute and have u had any issues after mods?

[blower]

Thanks for that mate you've been a massive help. Ye heard the Apr maps run way too lean. Not good combination with an engine that already runs somewhat rich already. What sort of bhp are u running at the minute and have u had any issues after mods?

Actually its the other way round for the latest APR maps - the original ones ran a bit lean, and now they run too rich - which causes the newer revision of the injectors to foul the sparks. The AFR drops to as low as 10.3 at full torque around 4krpm.

I'm running stock BHP atm, but will be looking for around 230bhp, 330nm torque once i get the cash for a custom map.

I'm pretty heavily modded hardware wise though - have recently fitted wossner forged pistons, have audi r8 coil packs, Golf R/S3 intercooler, custom catch can setup, latest revision HPFP & injectors. Only thing left to work out setup wise is a sports cat downpipe and exhaust.

[Ryanforsyth91]

Fair play mate not taking any risks then aha. All the best with ur build I'll look forward to seeing how it all goes. Thanks again for all ur info