So I changed out my water pump and thermostat yesterday. What a difference. I won't bore you with the details as the process is already covered extensively in
Dan_Q's awesome DIY, but I will go through and highlight some of my findings and updated theories.
First of all, I really had a great time doing this. The past few projects hadn't worked out as planned, but this one was an absolute breeze. 3 hours total from the time I cracked the first bolt to when I got the last bolt back in. Only one real snag which didn't really hold me up at all and the results were immediately apparent (unlike my valve seal replacement, which I'm starting to think did absolutely nothing). The car now gets right up to operating temp and stays there, regardless of outside temp, cabin heat settings or driving style. I took it out today for a nice spirited drive along some of the parkways around here and it was running great. No more thick black clouds. I noticed a few little wisps of light smoke coming off a stop, but I'd expect that with the oil I'm (still) burning. But no more black diesel-looking smoke and I averaged close to 24 mpgs over the course of the drive, which was amazing considering how heavy my right foot was feeling.
First off I was greeted to this lovely sight upon removing my intake manifold:
Just absolutely soaked in oil. Even had some pooled up in a couple of my injector wells. Lovely.
Looks pretty close to how it did before my carbon cleaning (which I did less than 10k miles ago).
My tumble flaps weren't all caked-up like they were before I cleaned them last year, but instead were literally dripping with oil. Like actually dripping. Wonderful.
Here are my injectors. I bet I've been getting great spray and atomization with all that oil sludged up on top there.
I still had about half a can of BG ISC from back when I did the carbon cleaning, so I used that to clean off the injector tips before tossing them back in.
Lastly like I said there was one snag, which was sort of major but I'm not worrying about it for now. When I was reinstalling one of my intake bolts, barely even getting it in and way before it was properly torqued down I heard a loud creak and then a snap immediately after. The bolt lost all resistance so I pulled it back out to see this:
So I'm going to need to re-tap that thread and be a little more careful with my bolt torquing in the future. Could have just been bad luck, or it could have been me reusing TTY bolts (not sure what these intake ones are) and not following torque specs last time I removed and reinstalled the intake. Either way I'm down one bolt at the moment and it's running fine so I'll fix it later.
Now, for updated theory time. Basically we're going back to square one (bad rings). Yeah, big shocker. So taking apart my intake system after doing all this work taught me a few things. First, let me show you what I found. This is my throttle body looking at it from the charge pipe side, aka the 'outside', right after the air is leaving the intake charge pipe and before it's about to enter the intake manifold.
The top image is the backside of the throttle body mostly closed, and the bottom picture is the throttle body plate fully open. It's a little hard to tell there with the bad lighting, but it was basically like night and day in there. Everything before the throttle body plate was clean as a whistle. Not a spec of oil, carbon, anything. Everything was all new and shiny looking like it just rolled off the factory floor. However on the other side of that plate looked like one of those sea birds from the Gulf of Mexico you saw people cleaning with toothbrushes on the news after the Deepwater Horizon oil spill. Absolutely crusted with jet black carbon sludge.
So I'm going to be trying out a few new things, but basically my valve seal theory came about due to my ECS catch can not catching any oil, which it should have been doing (at least that's what I thought) if I was in fact burning oil due to bad rings which would be causing extreme amounts of blow-by. But apparently out of the two hoses coming out of the PCV, the hose ECS's kit installs the can in-line with (the turbo hose - aka charge/boost hose) barely gets any oil at all, while the hose ECS's kit deletes (the intake manifold hose - aka NA/vacuum hose) is the hose that's doing most of the work venting the crankcase and dumping the oil into my engine. I don't know if this is intentional or a flaw in the design of the ECS kit, but I'm having a hard time thinking this was what it was designed to do. If I'm installing a catch can to catch oil, I want it to catch oil. Not delete the line that's actually carrying the oil and pressurized air and then install the can onto the line that's basically just carrying condensation. I didn't buy this catch can because I was having a problem with water consumption.
So that's now leading me to wonder what's happening to all that pressurized air full of oil mist that used to be getting injected directly into my intake manifold. I had previously assumed it was going to simply be rerouted into the other hose, the hose that the catch can was installed in. But I've been getting zero oil out of that hose, and now my engine block is starting to sprout oil leaks. First it was the feed line a few weeks ago (that whole broken bolt fiasco), now I'm pretty sure it's leaking out of both oil lines from the block and maybe even one other place (there are now three small yet distinct drip spots under my car on the garage floor). That, combined with all the oil in my intake system and injector wells and I'm starting to wonder if this catch can kit is over-pressurizing my crankcase due to the intake PCV line delete and causing oil to just escape my crankcase any way it can, getting into areas I'd really rather it not get into.
So I kept the can installed, but replaced the stock PCV line to my intake manifold. We'll see if this stop my oil leaks. In the meantime I've been pricing out a new bottom-end build and it's a bit pricier than I initially estimated it'd be.
Anybody have any ideas where I could cut some costs? I'm thinking I could probably find some stock Audi pistons out of a non-oil-burner for less than $900. Maybe out of a TTS or RS or something? I know JE has cheaper forged pistons but they don't have the concave head which I think is important in our DI engines to get a good A/F swirl/mixture.
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