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Black S3, first audi

Cookiez Jul 9, 2018

  1. Cookiez

    Cookiez New Member

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    Hi.

    Been stalking these forums for quite some time as ive had different golf mk4's since i got my licence eight years ago. The latest being a golf 4 25th anniversary. Long story short i wanted awd again as it was something i missed from my mk4 tdi.

    So when a S3 i had been following here in norway was posted for sale my first audi was indeed a fact.

    The car is a 99 model APY prefacelift

    Quick list of whats done to it (gonna fill this out later when i find the mods list)
    - Tuscan I-beam rods
    - Wiseco 9,25 pistons, stock bore
    - Large port head, but still stock small port inlet (how much of an issue is this?)
    - Frankenturbo f23 with chinafold
    - Badger5 TIP
    - Wagner FMIC
    - Movit big brake kit with 330 discs and porsche 993 Turbo calipers
    - powerflex black bushings in the entire front end, except for some solid subframe bushings
    - Integrated Engineering catch can
    - Forge silicone hoses for water and turbo outlet
    - inline fuel pressure gauge (want to change this to a sensor i can wire in to Ignitron)
    - Deatschwerks DW65 fuel pump
    - Zinram 3 inch turboback (also have a spare milltek 2,75 inch catback, for MOTs etc)
    - TFSI coils

    The car has a few issues
    - the filler plug on the transmission has a crack, it works and is driveable, but i guess its a matter of time before i need to do something about this. I already have a 02M transmission from my old TDI so will probably swap it in.
    - No AC (havent looked into what's wrong yet)
    - And the biggest issue of them all, there are no cupholders!

    2018-07-15 18.51.37.jpg
     
    Last edited by a moderator: Jul 17, 2018 at 12:10 PM
    Warsuperior and SamHendry like this.
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  3. Warsuperior

    Warsuperior Member

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  4. Cookiez

    Cookiez New Member

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    from what ive read the gear ratios arent to bad, but there are a lot of different ratios on the diesels, so will check the code on it next time im in that part of the country (it sits in a garage 8 hours away).

    Worst case i open it and transfer over the gears from the s3 and just use the housing :)
     
  5. Cookiez

    Cookiez New Member

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    So, had the car for a little while now, not had time to do anything before this weekend.

    Finally had some time and started on the wiring.

    Started by removing the ecu plug so i could add the extra pins.

    2018-07-15 14.10.53.jpg

    I bought patch wires from the local dealer so i removed the pin from the correct pin number and added the precrimped patchwire.
    Then i soldered on the rest of the wire. In this case i actually stole the two wires needed from the evap canister since this was being removed and i wanted to remove the wires they were perfect to reuse for this, meaning i had good terminals with the correct rubbergrommet in that end as well.

    2018-07-15 18.51.55.jpg

    Sadly i forgot to take pictures of the job completed, but the local dealer had give me the male instead of female end of the wideband plug so im picking that up today to finish the job. Gonna take a few more pictures of the completed job then.

    It also looks like the cover for the ecu tray hasnt been properly attached so i have this chalky residue all over the area below the windscreen, so i gotta figure out how to remove that.

    I've also reported my first post to get it updated with a more complete mods list.

    And lastly, a picture of the car sitting all pretty in the garage im renting :)

    2018-07-15 18.51.37.jpg
     
  6. Cookiez

    Cookiez New Member

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    So had a trip to the garage!

    Wideband sensor wired and connected (picture tommorow, home computer doesnt like flash)

    Tried firing it up, nothing happened. Checked that lambda etc worked, it did. After a lot of cranking it suddenly started the second i stopped cranking, fancy, so the car runs, not good of course with only a base map. But it's a huge milestone for me, first time physiscally altering ecu harnesses :)

    Tried to figure out the startup map, but after a several hours, no bueno...
    But i think i have a couple of things to check out.

    1. The fuel pressure gauge under the hood is dead steady at 2,5 bars, so i guess all the fueling is off at the moment. The golf has a 4bar so i dont have a spare 3bar to test with, so guess i gotta buy one.
    2. Dead time, the current values is about a millisecond off what the 550cc bosch injectors are specced as (550cc has longer dead time) so this again can affect fueling.

    So the plan is to fix those two issues and if someone has a startup/crank map they use with their ignitron it would be fun to see how yours look compared to mine. I guess they shouldnt be that different seeing as theres not much boost etc to considering during cranking.

    Also the N75 wiring seems to be bad. I get P0243 and P0245 thrown from the ECU, so gotta look into that.

    Sorry for no pictures, but my computer wont let me so i'll fix that at work tommorow.
     
  7. Warsuperior

    Warsuperior Member

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    You ran 550c injectors with base map on me7.5? what ecu are you using?
    You could borewash your engine with those injectors with oem map since they put in way lot more than original ones.

    I got myself 630cc injectors but I bought a tune for this size injectors. I did wideband conversion too and I am using golf 032H ecu
     
  8. Cookiez

    Cookiez New Member

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    As i wrote in the first post i'm using an ignitron ECU. So the basemap is configured for 550cc injectors.

    Had it been a me7.5 ECU it would already be up and running, been mapping my old golf for quite some time :)
     
  9. Cookiez

    Cookiez New Member

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    Had some more time to work on the car last night.

    Tried figuring out why it wouldn't start, got some amazing support from the guys behind Ignitron, i must say the support they've given is top notch.
    After a while they started suspecting that i didnt have the standard cam trigger wheel for an APY.

    A bit embarrased i didn't think of that myself seeing as it has an AJL big port head, i figured they would've swapped over cam trigger etc from the APY head, but it makes total sense for why it has trouble starting. Didn't have time to pull off the cam trigger sensor to verify last night as it was gettin pretty late, but im going out to the workshop again today so i can verify and change it in the ecu.

    The N75 was as simple as a blown fuse...
    The car was running with a manual boost controller when i bought it so i guess no one had bothered with the fault codes the car had thrown (the n75 was connected, but looped).

    Tried taking a couple of pictures, still a mobile camera and bad lighting.

    2018-07-18 23.54.01.jpg

    2018-07-18 23.54.16.jpg

    2018-07-18 23.54.28.jpg

    My office for the next few weekends :)

    2018-07-18 23.54.39.jpg
     
  10. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    Looks familiar... lol

    <tuffty/>
     
  11. Cookiez

    Cookiez New Member

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    Hehe, spent many weekends with a similar view in the GTI logging ME7.5

    A quick update on the support from Ignitron again, i have a 13" laptop with a odd low resolution aspect ratio, so some windows were to big for the screen and not possible to scroll in to see the missing info.
    Reported this last night and was expecting a answer in the likes of this being outdated hardware and a suggestion of using a different laptop. Which i would totally understand. But no! They just released a new version of the software that supports my resolution!
     
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  13. <tuffty/>

    <tuffty/> Badger 5 Edition...Its all about the flow... Staff Member Moderator Audi S3

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    I had the same issue with my netbook screen res... (1366x768) and reported it to him back when I first started using my IECU... Brian told me about the new release a little while back

    Works great now on my piddly little screen :)

    <tuffty/>
     
  14. Cookiez

    Cookiez New Member

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    That's actually the same resolution as i have on my 13 inch laptop. Maybe he already had the new .exe file ready for me then :)

    So, trigger changed, fired right up, been driving around a bit learning the software and started doing some adjustments to the VE table.

    Even dared going into boost, either the n75 is broken or i routed the hoses wrong, didnt get past 0,5 bar, which i assume is the wastegate opening pressure.

    Car ran 1,2 bar before i swapped ecu so not to worried about it being something wrong with the turbo :)

    My innovate AFR gauge also suddenly stopped working after the car stood idling for 30 minutes while talking to a buddy, it's now stuck at 22,4 (max reading). Read about the gauge and its apparantly a common issue. Not sure what i'll do about it, the gauge is nice to have, but looks like there is a lot of hassle with the innovates...
     
  15. Warsuperior

    Warsuperior Member

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  16. Cookiez

    Cookiez New Member

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    Vital information i forgot to add.
    I am already running a phenolic from big port to small port. But all that does is smooth out the transition, it's still a smaller tract going into a larger chamber.
     
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