Time for a build thread....big turbo

[NHN]

That's a fair test then, but I'm all for one to at least test other same parts where possible, to 100% eliminate the obvious.

 

[S3Alex]

That's a fair test then, but I'm all for one to at least test other same parts where possible, to 100% eliminate the obvious.

Totally agree,and the car has been logged on the road,but apart from the thermostat,and the rich running,nothing untoward has turned up,but the idling is still lumpy and prone to stall.

 

[Granta]

Just finished the read, amazing car and very informative read! Well done mate its come a long way and no slowing down by the looks of things! Hopefully the misfire gets resolved soon and the car is back on the road soon

 

[S3Alex]

Just finished the read, amazing car and very informative read! Well done mate its come a long way and no slowing down by the looks of things! Hopefully the misfire gets resolved soon and the car is back on the road soon

Thanks very much!

It goes well,regardless of this issue,and I'm hoping AMD get to the bottom of it soon(and I'm sure they will be glad to get my car out of the workshop too!).

Plenty of bits to go yet.

 

[S3Alex]

Thanks to everyone here,and a lot of good friends over on VAGOC,the list of things to check keeps getting bigger.

To add to the list are:

Crank and cam sensors
Injectors
Throttle body.

Oh for a 500bhp car with that engine that only needed a quick tweak of the carburettor.

 

[S3Alex]

Bit of a setback yesterday as Steve had to work on a supercharger pulley for a Jag.....

That's the consequence of having a car so un-standard that only one of the guys can do most of the complicated stuff on it.

But today....back on the case.

 

[Granta]

Oh well at least its in capable hands!

 

[S3Alex]

Oh well at least its in capable hands!

That's for sure,but rather than chucking parts at it,AMD are trying to track down and isolate the fault,and it's taking more time than either myself or they anticipated.

 

[S3Alex]

Oh well......not the throttle body.

Intake manifold coming off to examine the runner flaps and valve stems,and I think while it's off may as well delete the runner flaps.

 

[Granta]

I know the runner flaps are there for a reason obviously but has anyone proven any gains from removing them? I have seen them on these engines where the flaps have melted and stop the valve from closing properly !

 

[S3Alex]

I know the runner flaps are there for a reason obviously but has anyone proven any gains from removing them? I have seen them on these engines where the flaps have melted and stop the valve from closing properly !

There are gains to be had in both bhp and torque,as even in the open position,they still present an obstruction to incoming air.

They aid cold starting,and without them,and the mapping altered to take their absence into account,the car's cold start-up is like my old Escort's was......knobbly and noisy.

There's a nice diagram on one of APR's pages showing what they've found in removing them.

 

[Unitronic]

Time for some pictures,courtesy of Ben.

Remember this?




Here it is alongside it's smaller,older brother.....

Hi Alex.

Do you have any pics with the Heldex dif trancfer fitted to the engine? Was just wondering how much space you had from the turbo to the diff fitted to the engine? My turbo has 1mm gap beteeen the diff and turbo?

 

[S3Alex]

Hi Alex.

Do you have any pics with the Heldex dif trancfer fitted to the engine? Was just wondering how much space you had from the turbo to the diff fitted to the engine? My turbo has 1mm gap beteeen the diff and turbo?

Not sure if these help.....

In the first picture the propshaft is disconnected,but the second shows how tight everything is,with the exhaust,propshaft and turbo with its heat jacket on.

 

[15Degrees]

No room for fingers in there

 

[S3Alex]

No room for fingers in there

Exactly.

The heat jacket does rub very slightly on the propshaft rubber coupling,but it keeps the heat away from it.

 

[Unitronic]

Yeah exactly what I was looking for. That the GTX or the old GT pics? Just a thoguht did you upgrade the turbo bearing casings seeing you have the jacket on it? My GTX is a very tight fit to the Heldex in fact the outlet housing 1mm from the overflow cap?

 

[Unitronic]

 

[S3Alex]

Yeah exactly what I was looking for. That the GTX or the old GT pics? Just a thoguht did you upgrade the turbo bearing casings seeing you have the jacket on it? My GTX is a very tight fit to the Heldex in fact the outlet housing 1mm from the overflow cap?

That's the GT.

The turbine housing is exactly the same though so the comparison is correct.
The bearing housing is uprated on the new turbo.

 

[S3Alex]

More oddness.....

The logging turned up that the MAP sensor is over reading......meaning the ECU thinks there's more air going in than in reality,and it's overfuelling by 20%.

 

[Unitronic]

You still using the 2.75 inch MAF housing Alex?

 

[S3Alex]

You still using the 2.75 inch MAF housing Alex?

Yes....it's not that MAF or the housing,as the car has been running that setup before and after this happened unfortunately.

 

[S.]

hope you'll get it fixed soon.

 

[S3Alex]

And so to Thursday.....

Firstly a big thanks to Steve at AMDTuning,who got in at 5 a.m. this morning to start working on my car again.....that's what I call service!

There was another TFSi there,so the 2 were logged against each other,and what turned up was a drop in HP fuel rail pressure on mine,but good LP pressure and as we know,massive overfuelling.

So,that points to one or more of the injectors being wide open,which again fits with the fuelling issue.

Next on the menu is removing the manifold and injectors,replacing the RS4's with my old S3 injectors and testing the idling on those,once the inlet runner flaps etc have been looked at.

Runner flap delete kit is on order,for when the issue is sorted.

 

[Granta]

is it the injectors at fault or a sensor causing the ECM to keep them open longer do you think? Oh well at least some news then. i have a stage 1 map booked in for saturday!

 

[S3Alex]

is it the injectors at fault or a sensor causing the ECM to keep them open longer do you think? Oh well at least some news then. i have a stage 1 map booked in for saturday!

It's looking more like an injector problem at the moment but we'll know when the work is done tomorrow.

 

[S3Alex]

The plot thickens again....

Injectors and manifold are OK.

Steve tried the car also with my old S3 injectors,and it still has the rough idling problem.

 

[NHN]

Man this is getting me aswell, I want to know lol.

 

[S3Alex]

Man this is getting me aswell, I want to know lol.

It's certainly getting to Ben and Steve....one has to listen to me,and the other has to find the problem!

 

[KentKid]

Seeing the photos of the turbo's in this thread has got me dreaming of Revo Stage 3!

Maybe it's about time I joined the 400+ club...

 

[S3Alex]

Seeing the photos of the turbo's in this thread has got me dreaming of Revo Stage 3!

Maybe it's about time I joined the 400+ club...

Gone on.....you know you want to!

Your car deserves it.....and so do you.

 

[S3Alex]

The plot thickens again....

Injectors and manifold are OK.

Steve tried the car also with my old S3 injectors,and it still has the rough idling problem.

The next port of call is one of the breather hoses,which has a one-way valve in it,and leads down the back of the engine,so I'm hoping that gets the thing sorted.

We know all of the other areas like sensors are covered,and giving correct figures,and the plugs,injectors,are all OK,and the take-off for boost measurement etc are all fine as well.

Doesn't leave much!

 

[Dean_T]

I click into here and keep hoping its all solved....

I think a few of us on here are as hyped as you to see/hear its sorted

 

[S3Alex]

I click into here and keep hoping its all solved....

I think a few of us on here are as hyped as you to see/hear its sorted

Thank you.

I can't wait to get the thing back.

Diesels are fine but the DS3 hasn't quite got the same grunt. Lol.

 

[KentKid]

I took my S3 in to AMD Essex to have a few bits done over the weekend, and whilst I was there I saw another Ibis white S3.

This one was a bit different though – monstrous wheels aside, it looked fairly discreet from the outside.

With a stance like that, it wouldn’t surprise me if it was one of the most powerful S3’s around!

Wonder who it belongs to… ;-)

 

[S3Alex]

I took my S3 in to AMD Essex to have a few bits done over the weekend, and whilst I was there I saw another Ibis white S3.

This one was a bit different though – monstrous wheels aside, it looked fairly discreet from the outside.

With a stance like that, it wouldn’t surprise me if it was one of the most powerful S3’s around!

Wonder who it belongs to… ;-)

I think it belongs to AMDTuning at the moment!

Much though I like my DS3,I really want my S3 back instead.

 

[KentKid]

I think it belongs to AMDTuning at the moment!

Much though I like my DS3,I really want my S3 back instead.

Haha, chalk and cheese those two!

Much as I like the DS3's, it must feel like a fairly muted experience when compared with your S3.

I tried sending you a PM, but alas, it appears your Inbox is full... :-(

 

[S3Alex]

Haha, chalk and cheese those two!

Much as I like the DS3's, it must feel like a fairly muted experience when compared with your S3.

I tried sending you a PM, but alas, it appears your Inbox is full... :-(

Ooops...Inbox should be OK now.

I've had a couple of DS3s now,and really like the car.
Well put together,and does 60mpg,which I can't complain about,but it's just not as fast....LOL

But,on the plus side,I don't mind the dog going in the DS3.

 

[S3Alex]

Hoping for some good news today or tomorrow,re the hose,and if not,it's down to swapping out more sensors in the hope of finding a duff one.

The big problem is having no error codes to work from,and also having covered just about every other avenue along the way.

Work was held up by another car that's been occupying space needed for mine,but that's another story,and frustrating for both AMD and myself.

 

[Sevv]

hey mate have you come to the conclusion as to what has caused it to overfuel ? its quite frustrating indeed without any fault codes to work from, have you explored the avenue that the map might be making the car run rich?

 

[S3Alex]

hey mate have you come to the conclusion as to what has caused it to overfuel ? its quite frustrating indeed without any fault codes to work from, have you explored the avenue that the map might be making the car run rich?

Hi there.

The work continues.

AMD have now loaded a completely stock map and got the car running fine so the next step is to load Stg2+ and see how that goes.

If its an ECU or software issue at this point I don't know.