Quote Originally Posted by nat225 View Post
good work there!

probably drive the car hard every now and then? driving it hard for 20-30 minutes supposedly helps burning off the carbon build up according to some VW Audi literature.

I did that often at Lakeside Happy Laps time
Oh I do the usual Mnt Nebo runs where it pretty much stays in 2nd and 3rd above 5000RPM most of the time but that is not the problem....it's the inherent problem with DI without another set of injectors or a 5th injector (like toyota)

Quote Originally Posted by Bug_racer View Post
The leaking water pump on TSI engines is fairly common , as is the Carbon build up in almost all Direct injection engines . Everyone seems to have the same way of thinking that this is a problem , and if you have a problem then you search for a solution . Question then is what are you trying to achieve . No more Carbon build up on the intake ? But what about the injectors ?? A catch can isnt going to stop this from happening no matter what you do , Carbon is a by-product of combustion so unless you run the injectors in the manifold and run a catch can its not going to solve the "issue" . Alternatively you can treat it like a maintenance item and once in a while remove the manifold , clean the intake and clean flow the injectors . Changing the PCV will also help as the PCV gets blocked up with Carbon as well over time . I dont recommend catch cans as Ive seen quite a few rocker covers fail due to a one way valve not being able to operate correctly which then causes poor idling and dumps oil in the re/circ type catch cans .
Now to clean the intake takes more than just a few days , on average it takes me a week to remove all of the carbon on the intake / dividers , clean the manifold and clean and flow the injectors ( I had a special DI machine built for this purpose) . The hardest part is polishing the valves once all the carbon is removed to get the original shiny finish which slows the carbon build up down . I do this on my own car just before I race . Also the prices the OP mentioned is how much I charge for parts/labour for the work .
I tened to agree and disagree here, the catch will make a huge difference, friends don't have to top up 1L every month anymore. The problem is with the PCV valve, I guess a simple fix would be to put a mesh right under it so the cams don't flick oil right into the valve, try starting the motor with it removed and see t 3.000 RPM how much oil gets flicked and sprayed around, a mesh will no doubt fix this. Then once the thing fills up with oil and carbon (not so much carbon) the membrane, the umbrella one fails and you get boost in the crankcase which pushes the rear main seal out and leaks.

The best thing you can do is put a catch can on these things and remove the factory PCV valve and bock off the intake manifold, you don't need that much vacuum, you get enough vacuum from the intake to get rid of most condensation.

yes I know it will not fix the carbon buildup in a DI, you have to either have individual throttle body (no more reversion) or 5th injector or another set of injectors to clean the throats and valved

And yes its a cnt of a job and personally I would charge more because I know how anal I am with this but supply and fit a water pump is normally $1600 which does not include cleaning the intake, injectors etc. So I'd rather do it myself.

The injectors I left with the tips dunked in CLR and they came out like new, intake manifold is not bad at all, the plates are caked with carbon and here is why the manifolds fail, the carbon builds up on them and the flapper hits this carbon and eventually the flap gets jammed and the shaft (plastic) breaks and there goes your intake manifold, everyone I now who never installed the plates could not tell a difference and never had the manifold fail.

Well hopefully I get the damn thing back on the road this week and do some laps around Mnt Nebo