There's quite a few pipes involved

Secondary air system - red and blue (I removed in two stages)

N249 system in yellowy orange

will 4mm be ok i will be doin mine and have plenty of 4mm left ova from my dv and boost gauge

should be okay buddy you will need about 2 and a bit metres of it

Great thread!!

I'm keeping an eye on this for the N249 bypass mod, I know the rest of the secondary air system has already been removed on mine.

Steve

Okay one question - if the whole of the coloured-in stuff on that diagram is removed it leaves the top of the DV and the line from the intake manifold hanging.

So is it correct to connect one to the other? Does that make sense?

That's what this guide suggests: http://forums.vwvortex.com/zerothread?id=3111538

is there any reason why we shouldn't use a 15mm in/outlet version instead of a 19mm one? as I can't afford to go to expensive and a cheap catch tank has got to be better than no catch tank???

is there any reason why we shouldn't use a 15mm in/outlet version instead of a 19mm one? as I can't afford to go to expensive and a cheap catch tank has got to be better than no catch tank???

doing some searches on this it has said that you should use the same size id as the original pipes as it will affect flow if you step down a size. as the ecu does read this airflow aswell so could cause issues .

also the pipes can become clocked with crap if to small on the cranck end.

there is a write up on vwvortex saying the reasons not to use smaller id pipe will try and find it

should be okay buddy you will need about 2 and a bit metres of it

looks like i will be ordering some more then dnt think ive got that much left 3mm it is

Okay one question - if the whole of the coloured-in stuff on that diagram is removed it leaves the top of the DV and the line from the intake manifold hanging.

So is it correct to connect one to the other? Does that make sense?

That's what this guide suggests: http://forums.vwvort...read?id=3111538

I think I just answered my own question:

From here: http://www.seatcupra.net/forums/showthread.php?t=42406

OK, here's a guide how to remove your N249 valves. As in a previous thread of mine, i detailed what does the N249 valve do, but here's it again:

N249 is controlling the DV (Dump Valve). It is installed between the intake vacuum source and DV itself. When no current is switched to the N249 (default state), the DV will get vacuum or boost from the intake manifold. This is how almost ALL turbo cars are worknig. When shifting gears, you let off throttle, TB closes and vacuum is generated which can open DV to vent boost (which cannot enter engine, because TB is closed).

On never 1.8Ts (2000+) they introduced the N249 (along with lots of other stuff) which is a possibility for the ECU to open the DV any time (!), even during full throttle/acceleration. When the engine is running and turbo is boosting, there is no vacuum generated, but to open the DV (which is mechanical), vacuum is needed. This is what the black vacuum reservior on top of the engine is used for. When idling, shifting, etc - so when vacuum is available, vacuum is led into this reservoir from the intake manifold and kept inside using a check valve (white/black), so when boosting again, vacuum will stay there (air cannot enter into the reservoir).

When ECU wants to open DV durnig full throttle/acceleration, simply "energizes" N249, which will "de-select" the DV from the intake manifold (boost), and "switches" it onto the vacuum reservior. The vacuum in the reservoir will open the DV instantly and release your boost, which, in most of the cases (tuning, etc) is not that highly required . In the case ECU sees a little overboost problem, it can turn N249 on/off repeatedly for very fast (just as N75 is working), which will open/close DV all the time, trying to settle (lower) the boost level.

PROs: By removing N249 valve, you can prevent this bad habit of the ECU, and by removing N249 valve, you are removing an approximately 2mm narrow bottle neck restriction (ID of the N249 valve) in the line to the DV, which will result in a somewhat faster DV response. I am using the stock bosch DV, but it feels just as good as an aftermarket DV with N249 (restriction) inline. Boost curve is smooth and progressive.

CONs: Boost overshots/spikes may grow higher, especially in high gear/low rpm situations (using the small K03), which can result in a leaner condition (for the moment). These spikes depend on N75 type, wastegate setting and software programming, but they usually don't last long (0.5-1s max). In the case these spikes are very high (car enters limp even), minor adjustment on the wastegate can be done. Ibiza engine covers cannot be used anymore (by removing the accessories above, two mounting points of the cover are removed aswell).

is there any reason why we shouldn't use a 15mm in/outlet version instead of a 19mm one? as I can't afford to go to expensive and a cheap catch tank has got to be better than no catch tank???

im having trouble finding a 19mm without paying over the odds aswell

I noticed the ebay ones have 15mm which can be changed....can you not simply just buy 19mm nozzles?

something like http://www.airlines-pneumatics.co.uk/webcat/Detprod.asp?ProductCode=S010142

im having trouble finding a 19mm without paying over the odds aswell

I noticed the ebay ones have 15mm which can be changed....can you not simply just buy 19mm nozzles?

something like http://www.airlines-pneumatics.co.uk/webcat/Detprod.asp?ProductCode=S010142

im gettin some catch tanks made up with 19mm inlet outlets in alloy. same as the one in this thread!!!! £45 each +p&p or at a dicounted rate if there is an order for 10+

will it have the internal gauze layer or will it be just an empty can like most that dont work???

will it have the internal gauze layer or will it be just an empty can like most that dont work???

im assumin the ones he already does for motorsport have the gauze in but not sure ive never had one so dnt no wot works best??? did you get my pm about the other bits?? will wait to see what he says then post it up on here to see if theres any interest......is it best to have gauze in the catch tank??

u starting a group buy then bud :yes:

u starting a group buy then bud :yes:

im goin to see my mate monday night hopefully, i've sent him all the measurements for the catch tank so i will see if its got gauze in it or not and iron out a few other things, obviously the t piece and pipework wont be included it will just be the tank!!......also on the agenda are a header tank if we can sort the sensor and a power steering tank both in alloy so once all is good and we've haggled over prices and available discounts lol i shall put a group buy thread up to see if theres enough interest

heres a link to his site for you to have a look at some of the things he makes..... http://www.alloyracingfabrications.com/

Edited 8 February, 201016 yr by sivrs

hey budy yep got your pm just let me know what e says on monday buddy

the more oem looking the better or just oem fitment

all the best clive

hey budy yep got your pm just let me know what e says on monday buddy

the more oem looking the better or just oem fitment

all the best clive

hopefully they will be as oem as poss the header tank probably wont be round like standard but the same size and use the original mountings and SHINY

as soon as ive spoken to him i will pm you. is it better to have gauze in the catch tank?? :S

yes mate as it causes the small droplets in the condesation to fall minimizing the amout of oil vapour getting into the inlet track but if he has done them for motor sport he will know that buddy

yes mate as it causes the small droplets in the condesation to fall minimizing the amout of oil vapour getting into the inlet track but if he has done them for motor sport he will know that buddy

he probably does it was for my benefit, i like to learn

looks good would he just change the out let size on the universal one which has a 19mm inlet?

looks good would he just change the out let size on the universal one which has a 19mm inlet?

im sure he would alter them to suit yes if people are happy with the style, you mean this one??

Edited 8 February, 201016 yr by sivrs

If your going to build one,then go the whole hog and copy these.

http://www.42draftdesigns.com/categories/products/catchcans.html

If Carlsberg made OCC!

If your going to build one,then go the whole hog and copy these.

http://www.42draftdesigns.com/categories/products/catchcans.html

If Carlsberg made OCC!

they are

yeah thats the one!

how much hose will be required to fit the catch tank??

how much hose will be required to fit the catch tank??

approx 2 metres

I used around 1.6 metres but better be safe

P.S. it needs to be oil resistant hose not just standard silicon hose. It is quite a bit more costly than standard hose..