Project 400 Update

[Faheemo]

One currently un-explained side-effect is the car's hesitation to hold idle. It only occurs sometimes on the road, and can be induced by stabbing full-throttle to about 5krpm at rest and then backing right off - the revs drop, and rather than catching idle it just dies. ISV tested and cleaned, no difference. Lambda is OK as well.

It's not noticeable generally, but a pain in the butt if you're stopping at lights etc, dip the clutch, and it dies; this can be helped by using 2nd for a few secs before you roll to a stop to keep the engine turning over. Mihnea tried to sort it out while remapping, with no luck. It started occuring before the remap.

Hey Ross
I currently have the exact same idle issue with my car.
Changed ISV TPS and cleaned MAF , all to no good use.

On the Other Hand your car is making very good power with very little lag !!
Minhea has done a good job , i can tell as my car is still in tuning phase with more hardware and your figures are damn impressive for the hardware you got.
The big difference i note is that your boost comes in very early with the RS2 manifold compared to my Tubular manifold.

[K7ERG]

Idle problem. Stalling at junctions/traffic lights and on the move at speed if the clutch was held to the floor.

I had a very similar problem with my Astra Turbo. It uses a Bosch AFM as well and i also had a cone filter fitted. No matter what i changed sensors, filters, pipe work nothing helped.

I then decided to get the Cone filter out the engine bay and fitted in under the inner wing. (Similar position to where the standard intercooler sits.) Once i done this the problem was sorted and has never cam back. I guess its the AFM cant handle the hot air from the engine bay and gives the ECU false readings making it stall.

I havent worked on Audi's much but i am looking at tuning a S4 AAN in the future.

So thanks for the info on this thread and keep me posted

Hope this helps

Craig

[Ross]

That's an interesting thought Craig, never did get round to doing much with this. Cleaning up the ignition had helped - are you using an ABY igntion Faheemo? Have you managed to solve this? I'd be interested to know, as the engine is having an ABY head fitted, and when it's ready I'll be swapping it into my Avant; I am kinda hoping this issue dissapears in the process.

I will be trying to fit an RS2 airbox, so if I do have similar issues then it'll be interesting to see if this solves it.

Cheers
Ross

[K7ERG]

Standard airbox usually helps. Its mainly when using a Cone filter that this problem occurs very common on Vauxhall turbo engines.

Just bought a S4 AAN avant so will PM you sometime to get info on getting more power out the unit.

Craig

[CHEN]

Fitted my cone filter to my car a week or so ago and it started stalling a lot, but I gave it time and its getting better?!?! Is the ecu learning?

[Faheemo]

Well ive wrapped the airflow meter with insulation wrap and recently i just went over it again with fiberglass heat tape (not in picture) just to make double sure.
I also suspected that the cone filter pulls heat from underbonnet air thats been preheated by ex manifold and turbo.
Gotta try and change the location of the cone or make duct that isolates the cone from the underbonet heat.

BTW my cone filter sits in the oil cooler airduct at present.

[Faheemo]

Standard airbox usually helps. Its mainly when using a Cone filter that this problem occurs very common on Vauxhall turbo engines.

Craig

With the type of mods i got running the only option is a cone filter due to space constraints.

IIRC Prosty changed the make of his cone filter and the problem disspeared.

[kwlw]

Well ive wrapped the airflow meter with insulation wrap

How long you are running with such setup?

Actually, after my MAF got fooked in very hot summer day, I've talked with some guy who is skilled in electronic, and due to that knows his urs4 electrical bits quite well. He told me, that usually feed voltage for the MAF is typically too high, due to which MAF electronics is tend to overheat and fail. He offered me a zener or something like that mod, but it just stayed in the words, because I've got two spare MAF's.

Some cold day I've checked MAF metalic part when engine was cold as stone (just warming up), and that part was quite hot, about 30 degrees! So this may be an issue.

It is interesting how wrapping in warm climate affects this.

Sau

[K7ERG]

What power can the AFM cope with?

Craig

[Faheemo]

Well ive had mine wrapped ever since i installed my BB turbo. Thats more than a year now.
I'm more worried about ex manifold heating up the MAf too much, as they close in proximity. I'm doing the Zener diode conversion today to see what it yields.

BTW my MAF gives a full voltage signal(5v) @ 4200 rpm which means maf cant see more airflow than that .

[K7ERG]

I removed the airbox today on my S4 and put a cone filter on. no issues with stalling/bad running, but i have placed the filter down to where the cold air feed for the airbox comes in.

Only problem i can see as mentioned is the MAF gets alot of heat.

Craig

[A80Avant]

ross,i will be using your thread as a backbone to make my project go!
it seems that most parts are the same,i only have the injectors to begin with.I will try to use the RS2 airbox if it fits,maybe do some manifold masking to eliminate high temps to go over the filter and maf area,and also maybe i will cover the MAF with some heat insulator as well to keep it from getting too hot!

what did you manage to end up with powerwise?
Im also aiming for the 400+ mark and hope to achieve it!

[Jon441cc]

GT3071R install

ross,i will be using your thread as a backbone to make my project go!
it seems that most parts are the same,i only have the injectors to begin with.I will try to use the RS2 airbox if it fits,maybe do some manifold masking to eliminate high temps to go over the filter and maf area,and also maybe i will cover the MAF with some heat insulator as well to keep it from getting too hot!

what did you manage to end up with powerwise?
Im also aiming for the 400+ mark and hope to achieve it!

The RS2 box will fit but it needs trimming on the bottom... Its tight but it can be done Martin fix (Morten) had a cracking website with loads of pics of the but the link is now dormant


GT2871R Dyno

[Ross]

Those are some cracking pics Jon! lovin' the black...

@PapVas - glad to see my thread has been helpful. The RS2 airbox can be made to fit as we see in Jon's pic; the heart of "Project 400" is currently being transplanted to my Avant. I hopefully will have some pictures after this weekend. The RS2 airbox is going to be fitted, with a little modification!

Power was 428bhp with 2.0bar on the 3B ignition + RS2 intercooler. We'll see how it goes on the ABY...

PS - injectors is where I started too! (but ended up 'upgrading' them )

[A80Avant]

ross,how much boost are you running with the Gt3071R to produce the 428hp?