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Sandips (strange) build thread

Discussion in 'A3/S3 Forum (8L Chassis)' started by Sandip, Mar 20, 2011.

  1. S3 Nattie
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    S3 Nattie Quattro ist für sissies

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    Thats probably why your running pretty high power as a lean mixture tends to give you good power but its bad to run too lean for obvious reasons. Should be getting lambda values which welly has just said.

    Hopefully you can get your ECU sorted and get a proper known map on it.
    #41
  2. Sandip
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    Sandip Well-Known Member

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    It's a very rare map called 'Poo Map', it was probably due to this map that my cylinder head cracked, i want to do another logs to see egt's but i don't want to push my luck


    think it's a Superchip map but MTM also did chip changes early on so who knows. When Revo remove it i'll ask them to send it back so i can have a good look at it
    #42
  3. Sandip
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    Sandip Well-Known Member

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    Been in touch with Revo and thy'll do the chip change so Awesome can then flash Stage 2 :) Hopefully it'll make good power
    #43
  4. Welly
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    Welly VX220 SC Driver :)

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    Doesn't matter about the power, at least the engine will last. That map isn't the best. By any stretch.
    #44
  5. S3 Nattie
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    S3 Nattie Quattro ist für sissies

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    Really interested to see what you can get from your engine as your turbo looks strong from previous boost logs you uploaded.

    You going to get a 3" tip before you get it mapped
    #45
  6. Sandip
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    Sandip Well-Known Member

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    You mean Revo isn't the best or my current map lol If Revo S2 makes good use of my airflow and does everything else right then i would expect some strong realiable power, at the moment nothings right really
    #46
  7. Sandip
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    Sandip Well-Known Member

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    I'll be getting the 3"tip after the map, i'd like go to Bills to buy it and possibly dyno it on the same day, if fuelling,timing and boost needs adjusting i'll let Bill do it :) (even though i hate dynos)
    #47
  8. Welly
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    Welly VX220 SC Driver :)

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    I meant your poo map.... lol.

    I loved my Revo. I love my Badger 5 Stage 3 more, but my Revo did the job very well.
    #48
  9. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    LOL
    AMD is not AmD

    AMD make silicon devices - hehe

    Your replacement K04 is not performing like a normal K04 with those power levels & high airflow and sustained boost at that rpm. It looks like a hybrid to me... certainly not performing like a std car..
    check your injector duty cycles for no maxing out if your airflows are correct and not a happy maf.. (unlikely given the >1.5bar boost its holding at 6krpm)
    Last edited: Mar 22, 2011
    #49
  10. Welly
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    Welly VX220 SC Driver :)

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    Could it be to do with the high flow manifold fitted?
    #50
  11. superkarl
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    superkarl MAN OF STEEL

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    if it is i WANT ONE
    #51
  12. Welly
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    Welly VX220 SC Driver :)

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    LOL. :yes:
    #52
  13. Westy
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    Westy Double Dark Side! Diesel & 8P

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    Yeah good luck with getting one ;)
    #53
  14. Welly
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    Welly VX220 SC Driver :)

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    I'm glad I didn't hold out for the JBS Mani I must admit... I would still have been waiting.
    #54
  15. superkarl
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    superkarl MAN OF STEEL

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    speaking of mani's, wasnt there mention of some new unheard of items, or was that downpipes?
    #55
  16. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    hmm. i would be surprised if it was personally.
    #56
  17. Sandip
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    Sandip Well-Known Member

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    It's a 'nice' manifold but i agree with you Bill, it ain't going to improve my flow to the extent that it is doing

    At high rev/full boost the car missfires/pops quite a lot, is this detonation? I'm currently driving the car with the N75 unplugged
    #57
  18. Sandip
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    Sandip Well-Known Member

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    Ok, unplugged the N75 this morning before work, on the way home i gave it some 'welly' and high up in the rev range the boost went up to 14psi as the revs went towards 6k.

    So this has got me worried! Rang Bill and he kindly advised me that this sounds like boost creep, possibly due to a small wastegate or too much preload on the actuator.

    Some logs will be done later with the N75 unplugged
    #58
  19. Westy
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    Westy Double Dark Side! Diesel & 8P

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    14PSI with the N75 unplugged!!?? Jesus Christ!

    Where did you get you turbo from, have you no idea what internals it has?
    #59
  20. Sandip
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    Sandip Well-Known Member

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    So...here are the logs i did lastnight (with N75 disconnected)

    [​IMG]

    [​IMG]
    Last edited by a moderator: May 14, 2011
    #60
  21. Welly
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    Welly VX220 SC Driver :)

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    Creeping like a bitch there. Too much pre load on the actuator perhaps could be the issue perhaps.

    Interestingly, it's requesting different fuelling in the first screen shot you posed there. Still lean, but less lean.
    #61
  22. Sandip
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    Sandip Well-Known Member

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    Yeah, that's what Bill said, either too much preload or wastegate to small. 003 is ign and 101 is inj?? Or am i missing something lol

    But yeah correct, creepier than the yorkshire ripper! Would a mbc not cap the boost and stop it overboosting when the N75 is connected??
    #62
  23. Welly
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    Welly VX220 SC Driver :)

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    That sort of defies the point of ecu boost control. I'd be more interested in finding out why it's happening firstly.

    An MBC won't help this problem. You aren't trying to control a spike which the MBC would help with. The issue here is that when the actuator is open, the boost is still climbing.

    Whether air is being sent to the actuator via an MBC or the N75 is irrelevant, it won't help as you will still have the same issue.
    Last edited: Mar 23, 2011
    #63
  24. Sandip
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    Sandip Well-Known Member

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    Good advice! Is the best way to adjust it going to be to take the chargepipe off and adjust from above? Had a quick look lastnight and it looks kinda awkward to get at from the airbox side, couldn't even getthe spanner on it lol
    #64
  25. Welly
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    Welly VX220 SC Driver :)

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    Just clarify what you're trying to do so I can get a mental picture - adjust the preload?
    #65
  26. Welly
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    Welly VX220 SC Driver :)

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    Mental picture....

    [​IMG]

    LOL
    #66
  27. Sandip
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    Sandip Well-Known Member

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    Yep, i would like to try an adjust the preload, move the nuts closer to the end of the bar, 2 turns??
    #67
  28. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    nope - as i said to you last night
    its a physical thing
    wastegate (for whatever reason, and i suspect its not a std hotside/OR/ bigger than you think it is inside-aka hybrid of sorts) and the wastegate apature is too small.
    they're about 22mm std.. and if chinese castings or non-std casting are being used on it, maybe different size again.

    wellys hybrid crept initially.. 22mm std wastegate port was too small. ported it to hell to 29mm and all sweet after
    #68
  29. s3dave
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    s3dave TFSI Hybrid

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    Yes go for it, just remember your turns so you can put it back, its the other way thats risky without propper testing
    #69
  30. Sandip
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    Sandip Well-Known Member

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    I rang PSI Tuning Monday and they would like to see the car, i have had a look at the actuator and i would be able to adjust it but i would like Andy at PSI to check it over first. Spent a lot of money, the last thing i want is to void a warranty incase it is the wastegate that's the issue. Just got to wait now :(
    Last edited: Mar 23, 2011
    #70
  31. Sandip
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    Sandip Well-Known Member

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    Quick update : Took the car to PSI Tuning for them to have a look at what's happening with the boost issue. They took the car out and noticed the boost was creeping past 7psi with the N75 disconnected. They then checked actuator pressure made sure it was set correctly. Tried a N75j because unfortunately they never had a new F available, J caused major boost spike (30psi) that came off back to the F.

    Then bypassed the N75 totally, connecting actuator vac line to chargepipe, Simon the tech took the car out and boost was now holding 7psi, happy days, thought all i needed was a new N75. Took the car away (£40 lighter) 3rd gear pull (N75 bypassed), boost is still creeping! Took the car back straight away. They checked it again, actuator pressure is correct so they will now be contacting the turbo supplier with regards to my issue.

    I will be recieving a phone call/email this week as to what is going to happen, Pete at PSI told me that the £40 i paid will be refunded if it does come down to the turbo being replaced. I've recieved great service up till now from PSI and the fact this turbo ain't right is not their fault. They had it supplied to them set up, they fitted it. It should work, but it isn't :(
    #71
  32. s3dave
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    s3dave TFSI Hybrid

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    Do you think it needs porting?
    #72
  33. Sandip
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    Sandip Well-Known Member

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    Possibly, Bill mentioned that it could be the wastegate aperture that's too small. Ideally the aperture of the Borg Warner K04 needs to be measured against a oem KKK unit. Porting will most likely cure the issue but i'm leaving it up the PSI to rectify as they supplied the turbo
    #73
  34. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    your turbo holds too much pressure >6krpm to be classed as a normal k04.. and flows too much air..
    std wastegate port on k04's I have seen is 22mm, which is smaller than a k03s!
    I port the hybrids out to 29mm which is as far as you can go and still retain the penny seal
    #74
  35. Sandip
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    Sandip Well-Known Member

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    Thanks Bill, appreciate the input:)

    Just come off the phone from speaking to Andy at PSI, we have both decided the best option would be to remove the turbo and get hotside flowed and ported.

    It could be that the oem KKK unit was ok and didn't suffer boost creep because it had the cracks in the hotside, the Borg Warner K04 isn't handling the flow with this manifold, hopefully once ported this problem should be solved.

    Andy did advise me that once ported it may cause boost spike and increase the risk of rod failure so i will be fitting a UNOS mbc once this turbo has been ported. Next step after this may have to be rods before i get the map sorted.

    Would like to thank PSI for being so helpful on this matter and i would also like to thank Bill for helping me diagnose this issue, i never wanted to go hybrid but it looks like it's going to end up being one! Bugger!
    #75
  36. badger5
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    badger5 www.badger5.co.uk Site Sponsor

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    ported will improve boost control, not enhance spikes.. larger port will flow more for the same openening angle
    #76
  37. Sandip
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    Sandip Well-Known Member

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    So improve flow = same initial spike (26psi, N75f) but more controllable (no creep)?

    How much more do you think it can flow Bill or is that hard to say without actually looking at the turbo? would improving flow show in maf g/s?
    #77
  38. wibble111
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    wibble111 needs to scratch the itch

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    Bit off topic and a bit pointless but some of you may find it intresting, was speaking to a guy at work who saw and commented on my S3 and it transpires that he used to work for JBS and did the r&d work on your manifold sandip, he also designed a lot of their turbo developments aswell and he and one of his mates are in talks with some engineering companys at present to get the manifold cast/fabricated very shortly so may be available to buy soon at cheaper cost than JBS aswell.
    #78
  39. Sandip
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    Sandip Well-Known Member

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    From what i'm aware the K04 JBS manifold i have wasn't made here in the UK, middle east i think, could be wrong lol

    From what i am experiencing, putting a highflow cast manifold on a stock K04 isn't straight forward. Mine is not a hybrid and is struggling with the extra flow so if any cast highflow manifold that does become available for the K04 then porting the hotside to match the flow would save a lot of time and money in the long run :)
    #79
  40. Welly
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    Welly VX220 SC Driver :)

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    Thats definitely one for the book isn't it, and a lesson that needs to be heeded for those looking a high flow setup on the K04 in the future.
    #80

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