fitted fixed turbo, v3 mani, and downpipe now no boost???? help

[JUS3IN]

hey all, start at the begining, have a chinese turbo which was overboosting due to boost creep. sent it off to badger 5 and he done the porting of the hot side, while i was at fitting it all back together i decided to fit a relentless v3 manifold, badger 5 tip, and xs power downpipe and sports cat... took it out for a test drive 9 o clock last night and it was blowing and not boosting at all.... tightened up the cat to rear section this morning and the blow has gone but im still getting no boost, a few times it went up to 0.3 bar but quickly decided i was having 0... zip, zilch..... sounds like the turbo is spooling ok doesnt seem to be any air leaks and i hard wired the charge pipe to the actuator and tryed unplugging the n75.... im stumped, any ideas?

 

[JUS3IN]

also theres no fault codes?

 

[s3dave]

Orange pipe on securely? Actuator leaking?

 

[Prawn]

No boost at all? Even actuator pressure around 6psi? Sounds like no wastegate preload to me.

With the n75 bypassed so you're running straight from charge pipe to actuator, try in reading he preload until you're up at 6-7psi, then plug the n75 back in and see what happens

 

[JUS3IN]

orange pipe? actuator seem solid and an effort to move before i fitted it, was pressure tested before i sent it to badger 5.

 

[JUS3IN]

No boost at all? Even actuator pressure around 6psi? Sounds like no wastegate preload to me.

With the n75 bypassed so you're running straight from charge pipe to actuator, try in reading he preload until you're up at 6-7psi, then plug the n75 back in and see what happens

yeah no boost at all mate, when i first took it out for ten min last night it was floating around 0.5 bar.... then this...
sorry dude what you mean 'reading he preload'?

 

[JUS3IN]

maybe where i primed the turbo with the injectors unplugged its in limp??? no codes though... and direct charge pipe pressure would still be running .5bar right???? all the pipe work seems tight and leak free... theres no hissing or air...

 

[s3dave]

Orange pipe from turbo to charge pipe, be care full with the xs power manis as they can burn through them, if thats ok i would tie the wastegate shut and carefully go and test it, bearing in mind it could shoot up to ?? psi ..if it starts to rise its an actuator problem

 

[beachbuggy]

orange pipe? actuator seem solid and an effort to move before i fitted it, was pressure tested before i sent it to badger 5.

Before??!!! What about now? What if you set it up so the wastegate is still open? Won't matter how good the actuator is. Open is open

 

[JUS3IN]

What if you set it up so the wastegate is still open? Won't matter how good the actuator is. Open is open

set it up? the waste gate was tight shut by the actuator when i fitted it?

 

[s3dave]

who put the actuator on you or bill? bill will have set it up with the correct preload..

 

[Prawn]

Haha. Autocorrect fail.

I meant to say, try winding on the preload until you're up at 6-7psi.

No boost at all can only be down to the wastegate being open assuming the turbo is in good health as you would expect having just come back from Bill.

 

[JUS3IN]

the actuator went away with it and is still set as it was before all the work, it worked ok then? just pumped it up and the arm moves freely. i then disconnected and reconnected the turbo elbow silicone pipe and the clips were ****e, out of my drive she pulled to 0.7 bar so went to halfords bought new clips connected in the car park and on the way home 0.4 bar then down to 0.2 bar for 8 tenths of the way home.... oh and smoke because i forgot to pin the heat protection up and it was lying on the mani!!!

all i can think is the wastgate is sticking, bill tack welded the sleeve where the actuatror rod goes through cause he said it was sticking???

 

[JUS3IN]

the elbow looks good, no splits... stumped. should i try adjusting the actuator up??? also im running 0.9bar negative on tick over, it only used to be 0.5-0.6???

could this be cause by a leaking turbo flange/bad manifold fitment?

 

[JUS3IN]

im thinking leaky turbo flange or actuator adjusted wrong.... if bill didnt re-adjust it, forgot or didnt think he had to and it was adjusted by someone/previuos owner to compensate for the overboost it could be wrong? maybe i need to check this first. what a pig to get to with this manifold on... cant see the arm!

 

[JUS3IN]

she's sorted!-) after disconnecting the battery for an hour she's boosting lovely, a b it only to 1.1bar... gues thats what it shoulkd have been boosting on the map before the boost creep! one small negative ive tightened my turbo outlet pipe (orange/red pipe!-) no much and its split and is hissing like a mofo! no boost creep now tho so all great, cheers bill and tuffty and everyone else who helped much appreciated.

just gotta hope all them impossible nuts on that pig of a job hold tight... anyone who's planning on doing the downpipe and xs power manifold be warned its a nightmare, had to make tools and my hands are cut to pieces, arms are bruised and my whole body aches and im a well built hard working slab layer/block paver... if your an amatuer mechanic like me be warned allow three days, i done it all through the drivers wheel arch tho and dropped all four subframe nuts to get that darned downpipe in and it still took a big yank and lots of pain as my hands smashed the head and firewall lol! i'll do a full write up in a bit.... cheers.

 

[JUS3IN]

forgot to add i guess when i primed the turbo oil feed by turning the car over with the injectors unplugged the ecu went into some sort of safe mode?? anyone confirm? reset her by dissconnecting the battery and away?

 

[Dani_B19]

Glad youve got t sorted matey .

 

[JUS3IN]

cheers fella, no boost m,ade me panic... guessing the ecu must have been cutting injector pulses enough to inhibit boost....

 

[<tuffty/>]

Sorry dude, did get your PM but not had a chance to reply until now... I see you have it sorted though now...

Scratched arms etc (20v or 1.8t rash as its known as) is perfectly normal when working on these cars... tight, awkward, and 'I have to remove all this just to get to that?' are all common words/phrases used when working on these cars

<tuffty/>

 

[badger5]

some ecu's wont fire up at all after injectors have been unplugged for cranking up and getting oil primed.. Fault code clear after priming, before starting and it should be fine.

the wastegate was only undone on the outer nut for porting, and put back how it arrived.

creep should be gone now..

 

[JUS3IN]

Yeah I cleared the codes and she still wasn't boosting, after. Thinking a bit more about I'm wondering if a bit of grit or something got in the actuator sleeve as the boost was a bit sporadic... Still no boost creep now! And after all that work she feels slower lol, she's obviously been mapped to run at 1bar so I've lost about 7psi of extra creepy boost lol! Still least she's healthy now!-) cheers

 

[badger5]

the turbo was well parts cleaned and rinsed & blown dry before it came back to you. there is no space for debris in the wastegate sleeve. only when hot and expansion do they become fulyl "loose" and drop into the hotside..

You got back a far cleaner turbo than you sent me

 

[darren t]

Yeah I cleared the codes and she still wasn't boosting, after. Thinking a bit more about I'm wondering if a bit of grit or something got in the actuator sleeve as the boost was a bit sporadic... Still no boost creep now! And after all that work she feels slower lol, she's obviously been mapped to run at 1bar so I've lost about 7psi of extra creepy boost lol! Still least she's healthy now!-) cheers

what did you boost before porting of hotside??

 

[JUS3IN]

1.5 bar but was creeping and hitting soft limp around 1.4. Noticed it was much cleaner bill!-) maybe I got some grit on it somewhere, still its all working now anyways!

 

[darren t]

1.5 bar but was creeping and hitting soft limp around 1.4. Noticed it was much cleaner bill!-) maybe I got some grit on it somewhere, still its all working now anyways!

i don't think it's mapped for a bar.....do you have any logs at all??
i personally think it feels slower as you have robbed yourself of actuator preload what is your preload set at on vcds in mbar???the same as before or less??

 

[badger5]

http://www.audi-sport.net/vb/a3-s3-...boost-exceeded-intermitent-boost-problem.html

 

[JUS3IN]

i don't think it's mapped for a bar.....do you have any logs at all??
i personally think it feels slower as you have robbed yourself of actuator preload what is your preload set at on vcds in mbar???the same as before or less??

? not up to date on the logs and stuff yet mate only had the car a month, any pointers? theres no codes. as bill said he didnt adjust the actuator so what else could have changed? it was pulling 1.1 sometimes today.... the previous owner had it mapped apparently by a guy in a van with z-tune wrote on it, no website or sign of them online so alarm bells ringing!!! maybe it was just an excuse for the creep!
what do they run standard, 210 apy? and would the mods affect boost at all as its now got the full stanless mani and sports cat, piper cross panel filter, badger 5 tip, n249 delete....??? as its my first audi/vag car ive not got much to go on, i know today my mates aum stage 2 amd 1.8t is pretty much exactly the same speed on the duel carriage way from 2nd gear! he's running 208bhp and 245blsft..... hes obviously 200kg lighter...

my next job is a remap any how, was thinking a generic but is there any good custom mappers around in kent?

 

[JUS3IN]

after just reading 12psi'ish is standard im thinking it hasnt been mapped at all.... !? considering im running only 2.5 psi over stock lol... in a lot of ways if this is the case im happier due to the fact its been standard for more of its life!

i have no reciepts for the flash or anything, just the previous owners word...

 

[darren t]

after just reading 12psi'ish is standard im thinking it hasnt been mapped at all.... !? considering im running only 2.5 psi over stock lol... in a lot of ways if this is the case im happier due to the fact its been standard for more of its life!

i have no reciepts for the flash or anything, just the previous owners word...

I would get it mapped first I in same boat except I'm boosting over 1.5

 

[badger5]

log 115, 002,020

see what its being asked for 1800-1900mb request would be std

 

[kwistof]

my next job is a remap any how, was thinking a generic but is there any good custom mappers around in kent?

Nope- not really mate....there aint even any decent VAG garages in Kent tbh! lol

Personally I'd only take my car to two places in the UK for custom mapping....Bill @ badger5 or Nick @ R-Tech.

 

[darren t]

Nope- not really mate....there aint even any decent VAG garages in Kent tbh! lol

Personally I'd only take my car to two places in the UK for custom mapping....Bill @ badger5 or Nick @ R-Tech.

+1

 

[JUS3IN]

Nope- not really mate....there aint even any decent VAG garages in Kent tbh! lol

Personally I'd only take my car to two places in the UK for custom mapping....Bill @ badger5 or Nick @ R-Tech.

that sucks...

 

[JUS3IN]

log 115, 002,020

see what its being asked for 1800-1900mb request would be std

cheers bill, my first go at logging when i try this... just had a flick through on ross tech, so i log block 020 then drive in third from 2k to the redline and see what i get when? at the end?

 

[darren t]

Yep!!

 

[JUS3IN]

great, then obviously the other two blocks bill wants/needs to help diagnose,,, good stuff cheers darren you the man

 

[<tuffty/>]

You need to log all three blocks at the same time... foot to the floor in third not just crusing etc.. needs to see the load... I have done a small howto in the stickies including links to all the engine module blocks and Ross Tech wiki...

<tuffty/>

 

[JUS3IN]

great cheers dude, she's pulling and running well now, touch wood all my mani, turbo and downpipe nuts are holding too!-) fingers crossed! guess if she is standard and similar speed to my mates lighter stage 2 ko3s'd 1.8t thats not bad eh... if im around 210bhp and standard torque and he's at 208 with the 248 lbsft and what 200kg lighter and less drivetrain loss.

im thinking of doing a generic amd stage 1 for a while until i can sort the time to go up too bill, amd are 20min from me and i need a map before santa pod on the 7th july...

what does bill charge btw?

 

[JUS3IN]

actually there was one anomerly... well twice when she's cold she wont start first try, both times ive wound her over six to seven engine turns let off then starts second attempt. once she's warm she starts great? started first time every time before... do have my oil just above maximum from a slight overfill?

also had a **** fit when my car flashed a massive red light at me repeatedly as i drove the duel carriage way today, my mate said ti was brakes, pushed my button and yes low fluid.... wondering if the heat from the mani has affected it??