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  1. #1
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    2.7T APB (2002 Allroad manual) - engine cleanup Kobmivalve, EGR, PCV, SAI, oil catch

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    With the engine out, I want to clean up the mess of hoses, lines, valves, etc. and install an oil catch can.

    a) I removed the Kombi/EGR valves off the heads, and plugged the holes in the heads (M12x1.5 bolt with black RTV).
    b) I removed the SAI pump

    Next, I want to clean up the crank ventilation system.

    There seem to be 3 places where fumes are drawn OUT. 2 on the heads, and one into the manifold on the back side. These 3 lines go to the "Distributor Piece".
    There 2 paths to return them:
    1) under vacuum, via check valve into the inlet under the throttle body (located slightly on the passenger side part).
    2) under boost, via 'pressure limiting valve' (plastic thingy (not sure what Audizine speak is for it) on intake Y pipe) into the intake Y pipe

    a) Where would the oil catch can best spliced in?
    b) Are all 'paths' retained? Or is there a recommended 'clean up' to simplify?
    c) If retained, I would replace the brittle plastic with regular rubber hoses/clamps (re-using the respective 'connectors', and hose clamps to make the connection)

    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com

  2. #2
    Forum Moderator Four Rings Gumby's Avatar
    Join Date
    Sep 06 2008
    AZ Member #
    32779
    My Garage
    01 allroad, 01.5 A4 TQM, 06 Triumph Daytona 675, 14' Aprilia Dorsoduro 750
    Location
    Bellingham, WA

    Retain all the hoses, and slice in the catch can between the distributor piece, and the pcv valve. And yes, you can rebuild the spider hose with heater hose, or silicone hose.
    -Matt-
    B5 S4, B5 A4 Moderator


    2001 static, 6mt swapped, stage 3 allroad on a diet
    2871r'd 2001 A4 1.8t - daily/race car Build thread


    You may think I'm not online. But I'm always here. Even if I'm not posting. I'm always here. Scrolling. Judging.

  3. #3
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    ACF activated charcoal system 2.7T cleanup

    I am looking for good detailed instructions and suggestions how to clean up the ACF system on my 2002 Allroad APB engine (assuming is does perform vital duties in 'off road use').

    Can it be just completely removed, all check valves and the N80 solenoid removed/disconnected and the connections on the block/intake manifold and turbos blocked off?

    Any good DIY write ups, schematics and photos?

    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com

  4. #4
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    Quote Originally Posted by Gumby View Post
    Retain all the hoses, and slice in the catch can between the distributor piece, and the pcv valve. And yes, you can rebuild the spider hose with heater hose, or silicone hose.
    Thanks. Any suggestion for a 'low cost yet functional' catch can?
    The catch can will then only remove oil 'under boost'; fumes under vacuum are still going directly via non-return valve into the intake manifold port (under TB). Is the 'boost' path the undesirable one only (since it messes up the Y pipe, TB, bi pipes, intercooler, turbo compressors)?

    What size/type hoses (heater hose) is a good fit?
    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com

  5. #5
    Forum Moderator Four Rings Gumby's Avatar
    Join Date
    Sep 06 2008
    AZ Member #
    32779
    My Garage
    01 allroad, 01.5 A4 TQM, 06 Triumph Daytona 675, 14' Aprilia Dorsoduro 750
    Location
    Bellingham, WA

    Quote Originally Posted by vtraudt View Post
    I am looking for good detailed instructions and suggestions how to clean up the ACF system on my 2002 Allroad APB engine (assuming is does perform vital duties in 'off road use').

    Can it be just completely removed, all check valves and the N80 solenoid removed/disconnected and the connections on the block/intake manifold and turbos blocked off?

    Any good DIY write ups, schematics and photos?

    Take out everything from the n80 to the engine, and cap the intake manifold, and turbo inlet pipes. The n80 will be allowed to purge, while maintaining a closed evap system. the ecu won't know the difference if the engine is sucking up the fumes, or not. You can also relocate the n80 from the top of the intake manifold to inside the fender if you want to get it out of the engine bay.

    You can also remove the charcoal canister under the spare tire well, and tee the hoses back together without getting any codes from the leak detection pump.
    -Matt-
    B5 S4, B5 A4 Moderator


    2001 static, 6mt swapped, stage 3 allroad on a diet
    2871r'd 2001 A4 1.8t - daily/race car Build thread


    You may think I'm not online. But I'm always here. Even if I'm not posting. I'm always here. Scrolling. Judging.

  6. #6
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    Quote Originally Posted by Gumby View Post
    Take out everything from the n80 to the engine, and cap the intake manifold, and turbo inlet pipes. The n80 will be allowed to purge, while maintaining a closed evap system. the ecu won't know the difference if the engine is sucking up the fumes, or not. You can also relocate the n80 from the top of the intake manifold to inside the fender if you want to get it out of the engine bay.
    You can also remove the charcoal canister under the spare tire well, and tee the hoses back together without getting any codes from the leak detection pump.
    Gumby, I would assume a custom tune can take care of the ECU part. Under that assumption (waiting for confirmation from the tuner): what can 'go'?

    Connections to take care of that I see:

    a) remove canister and lines
    b) remove N80 solenoid
    c) plug the lines going to the compressor intake side of the turbo
    d) plug the line that goes into the intake manifold under throttle body. Is that the only connection to the block/vacuum?
    e) remove 2 non return valve
    f) remove associated connecting lines

    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com

  7. #7
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    Tuner confirmed: tune will be modified to take care of N80.
    Are my suggested mods then correct? Starting cutting soon....


    Quote Originally Posted by vtraudt View Post
    Gumby, I would assume a custom tune can take care of the ECU part. Under that assumption (waiting for confirmation from the tuner): what can 'go'?

    Connections to take care of that I see:

    a) remove canister and lines
    b) remove N80 solenoid
    c) plug the lines going to the compressor intake side of the turbo
    d) plug the line that goes into the intake manifold under throttle body. Is that the only connection to the block/vacuum?
    e) remove 2 non return valve
    f) remove associated connecting lines

    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com

  8. #8
    Established Member Three Rings MCargill12's Avatar
    Join Date
    Nov 10 2012
    AZ Member #
    103832
    My Garage
    Tools
    Location
    Northshore MA

    bump, interested in how that worked out. Trying to clean up my bay a little bit

  9. #9
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    Quote Originally Posted by MCargill12 View Post
    bump, interested in how that worked out. Trying to clean up my bay a little bit
    Still in the process of putting the engine back together. Also looking for best/easiest ways to block lines. Any suggestions for c) and d)
    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com

  10. #10
    Senior Member Two Rings rusky04's Avatar
    Join Date
    May 04 2007
    AZ Member #
    17773
    Location
    PA

    nice, take a lot of pix, im in for the results

  11. #11
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    Yeah.
    Still struggling to figure out which goes where, since 'old engine' I use for reference is a bit different from 'new' engine ('injection pump' for example), and new engine had some stuff removed (SAI pump, turbos, etc. for example). Both are APB.
    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com

  12. #12
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    Reviving and continuing:

    SAI pump gone.

    EGT/Kombi removed, cut matching thread, bolt and RTV. Plugged. Done. Will be tuned out.

    N80 removed, hard lines cut off fuel rail and ground smooth. 2 lines ("C)" in schematic) to turbo inlet pipe plugged softline with matching screw/RTV. Still need to plug/double check the "d)" plug. N80 will be tuned out.
    Mixing up front/back on fuel line, still thought I had not removed N80 lines. Cut what was there, only to find out that was the N249 hard lines (want to keep)

    N249: (which I want to keep). Will either plum the system up with soft lines, check valve, or use a 2nd fuel rails and modify correctly. Could use some good photos to match up with the schematic what line to run (and where they connect on the car site).

    Spider hose: My APB version is the suction jet Y pump version. Pipes still flexible. Would like to incorporate catch can (have cheap one on hand), but don't have a schematic how to best do it (would then replace corrugated plastic with hoses, but keep the connectors).

    Spider hose schematic: https://www.dropbox.com/s/p2ltu4f0rj...0schematic.jpg
    Spider hose photo: https://www.dropbox.com/s/nt2v4hz6f7...20DSC01836.JPG
    2Bennett cost prohibitive: http://www.rastta.com/images/breather.jpg
    Simple schematic, not sure if all plugs/connections/lines/checkvalves are shown: https://www.dropbox.com/s/8x431bcyy9...0schematic.jpg
    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com

  13. #13
    Registered Member One Ring
    Join Date
    Oct 18 2018
    AZ Member #
    429169
    Location
    Shopshire, UK

    Was there any outcome? Want to fit a catch can myself, but someone else's experience is always helpful...

  14. #14
    Veteran Member Four Rings
    Join Date
    Feb 20 2010
    AZ Member #
    54926
    My Garage
    2009 Dodge Journey, 1998 Passat AEB, 1999 Passat AEB, 2000 A4 ATW, 2002 A6 3.0/2.7T tiptronic KLR250
    Location
    Brighton, MI

    Car has been running like that for a few years.
    Currently waiting for me to put upgraded (rods, bearings, piston rings, seals, oil pump, timing) block and freshened up heads together.
    Then new turbos (likely going with the 67mm billet compressor hybrid I am running on my TT225). Then swap engine.
    Currently running 750cc injectors, but likely will need to go to 970cc Bosch and Walbro. See how fuel pressure looks like at idle. May modify stock FPR (bottleneck).
    Also will take out almost new CM FX400 6 puck clutch, too much chatter for my taste. Have RingerRacing full face stage 4 on hand.
    Also have water/meth on hand for lower IAT (running FMIC already).
    Plan is to run E85 in the summer, 93 in the winter.
    https://www.dropbox.com/s/ix9jmesmkd...0logo.jpg?dl=0https://www.dropbox.com/s/ix9jmesmkd...0logo.jpg?dl=0
    01 Allroad Tiptronic, TCU tune, mild stg 3 (350 HP) tune (stock injectors) KraftwerkTurbo TM1. Lower, Wider. Custom tip vent pod with Podi
    02 Allroad 6 spd, Kraftwerk Turbo TM6, 750cc, 3" MAF, piggy, FMIC, CM stg 5 (hate). 30 psi at 3600 rpm. Needs stronger rods (coming).
    05 Golf TDI
    Looking for 2001 A4 1.8T quattro manual with blown motor
    www.regulatorfix.com
    www.kraftwerkturbo.com

  15. #15
    Veteran Member Three Rings
    Join Date
    Jun 07 2014
    AZ Member #
    250206
    Location
    phila pa

    just curious, will all this work on a BEL engine?? do i need a catch can?



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