NefMoto

Since putting on my AWE side mounts and shrouds I've been getting a honking/horn type sound coming from my airbox from 3,000 rpm to 4500 rpm when applying light consistent throttle and usually when the boost gauge is at 0 or slightly under vacuum still.  Has anyone experienced this after installing intercoolers?  Can't seem to figure it out and it's driving my crazy.

Honda kid:

Shit son, your blow off valve be TIGHT. That a Greddy?

Savage:

Nah, I got that MALLARD.

Amazes me after taking it to a shop, talking to AWE, posting on three different forums, no one has experienced this before.  It's like I'm the first guy to install AWE intercoolers on an s4.  Looked over it for an hour at a shop today can't find anything wrong.  Only thing online I can find is porsche guys bitching that the 710N valves (which I have) honk...

Yup, diaphragm style diverter valves are known to honk

I have 710N's and they don't honk.

Mine didn't honk either until I installed the intercoolers which you DON'T have dillenger.

Why not just swap the dv's and see?  :-\

Yeah I will but its going to cost me $300 to get some forged ones because I don't have any others

300 dollars where are you buying them from? What dv's cost that much? maybe 200 for brand names.

? Everywhere I've looked a good set is $150 per dv... If you can find some for $200 please post the link as I'll buy them right now.  Also I don't want bailey's because I already have 2 that stuck open after 30k miles...

Blake, this is all in your mind.

Post a video!

The 710N's on my RS6 honk. Was thinking about playing with the n249 map to see if i can dial it out...

Baileys just suck period. I buy them from Overland out of california, they none branded billet dv's Overland sells alot of eurospec brand stuff. They
are 50 to 80 bucks depending how many I'm buying. http://overlandparts.com/pages/index.php (http://overlandparts.com/pages/index.php)

Yeah those are a good deal, but I can't find any reviews or information on them.. And I can't tell if they are diaphragm based or piston which is what I want.

The ones I've got in the past have a double oring piston the old ones like 6 years ago were diapham.

Are you periodically re-greasing/cleaning them? All the aftermarket (piston type) should be roughly about the same. The bores get scored if they are not maintained well, and can stick like you describe.

You can't take baileys apart, so they are non serviceable, AWE told me to buy new ones, they don't stand behind the product so I'd rather buy something like forge that you can take apart yourself and fix.

So is the honking sound a leak or is it the diaphragm just vibrating somehow?

the Honda kid joke totally has me imagining this car honking like a duck..lol

I think its a diaphragm vibration.  No leaks, doesn't seem to do it at all when its hotter out.. I dunno only thing I keep coming up with is threads and thread of audi TT and porsche 996 guys bitching about 710ns honking exactly at the same RPM i'm experiencing them honking at.

well order some from the link I posted ;)

Meh they don't look that great, and they don't say if they are diaphragm or not, and only list the 1.8t as an app when that company builds 3.0 stokers.. seems weird they wouldn't list it as an app

stop futzing around and just get 710Ns

He has 710N's. That's the issue.

lol

Then order them straight from eurospec. They are billet, and 70 bucks each. ;)
They are the same as overland.

Oh. LOL.

forged it is

this vibration could come from what though? compressor surge?

Air escaping through a very nearly closed valve. I'm about to start investigating if the N249 can be used to get rid of this.

 that's a leak. but possibly an induced "leak" via N249.

Does the DV have a weak spring in it from use/being old?

has the DV been pressure tested?

Why mess with the software before it's even been checked that a part may be failing?

In short, the N249 controls the DV but this isn't normal operation for the DV right? They aren't supposed to honk.

maybe his N249(and other peoples, the Porches, etc) isn't operating properly?, vacuum leak?, boost leak?

In these cases, is the N249 even fitted still?

Is it possible to log the N249 duty cycle to see if it has anything to do with the duck mating calls?

Do you have your DVs installed the stock way?

That's the first thing I asked mallard to check.

Fairly sure it's similar to the effect of letting the air out of a balloon with the end pulled tight. It's not leaking, just flapping near the transition form vac to pressure.

N249 intact. DVs are tested and fine they are 710Ns I bought new about 8 months ago. No leaks.

So, although my issues may be slightly different to the OP (the rs6 comes with 710P valves which have softer springs) as the symptoms are identical, I think the input is relevant. My 710N valves are brand new and have always made the noise.

Yesterday I made changes to the n249 maps SVDLDUVS and KFSDLDSUA and the noise has since stopped. Obviously I'll monitor it over the next while.

I'd be surprised if an intercooler swap caused enough variance on the high pressure side of the valve to require a change, but I'd also be keen to know if changing these maps helps too.

What maps did you alter, mind posting of a screen shot of the changes so I can give it a try?

I just altered the SVDLDUVS and KFSDLDSUA maps mentioned. As you're running an S4, you dont need to get fancy - try adding +15% to all values in both maps & see if it helps. My Rs6 is a bit different and i had to copy some of the s4 values over as one of the tables was zero'd across the board.

Happen to know the address's for the m-box on those maps? 

SHOW ME THE RAND!

^^ :)

I'm in a good mood today though, so here's a bone.... You'll need SDLDSUA instead of KFSDLDSUA as the S4 has no nmot axis for this map. Map addresses are for 8D0907551M (360857)

SDLDSUA (16x1) = 0x11119
SVDLDUVS (8x1) = 0x196F5

Factors and other stuff can be had from the fully defined G box file that's floating around. ;)

I told mallard I'd give him the addresses for 3.4 rand (roughly 34 cents). I was just messing with him :)

I sent him an xdf with them included last night.

Still don't have my rand :(

So far increasing both those map by 15% has eliminated my honk  :)

Great news :) Do I qualify for Rand too please? :-D

We might have to unionize. My rand still hasn't arrived.

Tuners of the world unite :) Maybe we can renegotiate for a good Bunny Chow recipe if he's from SA?

So this hasn't eliminated the problem but has made it better... Ultimately I think I'm going to have to get some forged piston type diverters as this noise is quite annoying when cruising on the highway under light throttle situations.

could give these a try:

http://www.ebay.com/itm/25MM-BOV-Bypass-DV-Dual-Piston-Blow-off-Turbo-S4-A4-VW-Golf-Jetta-1-8T-B5-Silver-/380683026519?pt=Motors_Car_Truck_Parts_Accessories&hash=item58a27a0057&vxp=mtr (http://www.ebay.com/itm/25MM-BOV-Bypass-DV-Dual-Piston-Blow-off-Turbo-S4-A4-VW-Golf-Jetta-1-8T-B5-Silver-/380683026519?pt=Motors_Car_Truck_Parts_Accessories&hash=item58a27a0057&vxp=mtr)

If the rough changes helped, why not refine the values where your having problems? Surely this is the essence of good tuning?

Sounds to me like you're trying to tune out a hardware problem.

SDLDSUA is predicted delta pressure threshold during negative pedal gradient

SVDLDUVS is pressure ratio threshold

Can you explain why these should be tuned here?

Just get Forge FMDV008s and be done with it. I am running those for two years now, serviced every year, and they work perfectly fine, however I still think if you would get another set of new 710Ns from an official dealer, your problem would be still solved. Many people run these without any issues with AWE or whatever intercoolers, and they don't have this issue. It is also possible that the sound has nothing to do with the DVs, it just started to happen right after installing your SMICs, or maybe something is rubbing into something after your installation and you only hear it depending on engine movement. Did you clean the SMICs before installation? Maybe you have something in of them that makes a noise however it's still big enough so that you can't blow it into your engine.
I am sure you can find someone in your area who can give you a working set of DVs for 30 minutes to check if it is actually the issue, hell I can even send you 3 pairs of DVs to test, however that would be inefficient. Even your original DVs would work for a test. I am glad I even put broken parts in the store, who knows what I am gonna need 'em for :D

EDIT:
Also ... which 710N do you have exactly? The part number is 06A145710N and ecstuning does not sell the Bosch one, they list the official part made by 'Kayser' which I find hard to believe. The official bosch part number is 0 280 142 114

The 710Ns I have are from pure motor sports and are like 10 months old.  The AWE intercoolers I installed were brand new sealed, so I really hope they didn't have anything inside them or that's a major fail on AWE's part... And I do believe its the DVs honking because it only does it when its cross over from from vacuum to boost and these changes to the maps have helped some.  Also I have found numerous threads mainly from audi TT or porsche 997 guys complaining of this exact problem around the 3500 rpm range under light throttle where I am experiencing the same problem.  I have bailey's that need to be serviced, I think I will just service them and throw them on and see if it fixes the problem.

Always flush ALL intercoolers before installation, new or used.

Yeah I must of missed that duck inside my brand new awe intercoolers.

http://www.youtube.com/watch?v=Mh85R-S-dh8