Project: RS2 ABY

[TimE-J]

Good luck on getting it sorted!

[Christophski]

Hope you get it sorted successfully next week bud

[djh]

is mrc going to be mapping it? thought you'd paid prj to map it?

[prj]

He hasn't really paid me to map it, it's just on a run in map.
I think MRC is going to try and see what is wrong with the car and why it's not making boost.

[Sonic]

I think MRC is going to try and see what is wrong with the car and why it's not making boost.

Correct, no plans for them to map it.

[Ross]

I'm sure Sonic will update on this later... but it's not the timing, it was out 1/2 tooth but that has not sorted the boosting problem, at least it's correct now though.

And it's holding 1bar for ages on a boost leak test @ MRC, so I can keep banging my drum on that. It's not a boost leak.

...still no idea what is the cause of the over fuelling

Next step is to fit his replacement TPS, is that a simple job? Looks to me like TB out, unbolt old, fit replacement, refit TB. Any calibration or careful lining up required?

[prj]

What's the point of touching the TB?
Check the opening angle with VAG-COM. If it shows 90+ deg you are good.

How are you doing the boost test? Are you keeping the intake plumbed up?

[Jamo]

I'm sure Sonic will update on this later... but it's not the timing, it was out 1/2 tooth but that has not sorted the boosting problem, at least it's correct now though.

And it's holding 1bar for ages on a boost leak test @ MRC, so I can keep banging my drum on that. It's not a boost leak.

...still no idea what is the cause of the over fuelling

Next step is to fit his replacement TPS, is that a simple job? Looks to me like TB out, unbolt old, fit replacement, refit TB. Any calibration or careful lining up required?

shock, Well Doug knows how to pressure test on S2 considering how many he's built and has his own car.

Any chance MRC can pop their own chips in as a test on the car?

[prj]

Any chance MRC can pop their own chips in as a test on the car?

Yeah, mapping can fix mechanical problems

P.S.
Sonic's N75 duty %

80	80	79	77	75	69	57	69	97	98	99	99	99	99	99	98

Sonic's target boost on 4 bar MAP

1.57	1.70	1.80	1.80	1.80	1.80	1.80	1.80	1.80	1.80	1.80	1.80	1.80	1.80	1.80	1.80

Sonic's boost cut on 4 bar MAP:

1.80
2.01
2.15
2.15
2.15
2.15
2.15
2.15

Yea, if your turbo is making 1 bar at 60%+ N75 duty cycle and going massively rich, that air is going somewhere other than the engine.
To anyone that knows anything about mapping, that is kinda obvious.

I'll fix the thing next time I'm over, if you are unable to.

Last time I will ask - are you keeping the TB plumbed into the IM when doing the boost leak test?

[Sonic]

So yes, i took it up to MRC this morning.

Doug and Chris did the pressure test - they said it was solid, which matches the result myself and Ross had. It is not a boost leak, from anywhere on the inlet at least.

They adjusted the timing slightly and it was out, as expected, however no change - the car is still performing horribly when you give it some throttle and is running rich

They suspect either TPS (which i already have a spare one of) or something funny to do with the injectors, map or ECU.

I am going to change the TPS and the stock NB lambda and see where that puts me.

If no change then im going to swap ECU and FPR with Ross and give that a go.

If that doesn't work then im going to burn the car

[prj]

Your ECU IS the same as Ross with boost and timing dialed down and injectors slightly rescaled (you have 510cc he has 550cc).

Still waiting about the answer regarding boost leak test.
I'm 90% sure I know exactly what's wrong with this car

[Sonic]

I won't pretend i understand the info you posted, but i'm sure it's useful

Last time I will ask - are you keeping the TB plumbed into the IM when doing the boost leak test?

Yes. The catch-tank return into the MAF hose was blocked off, but everything else was left alone, including the TB, and it held 1-bar solid.

Do you suggest i remove the TB from the mix and just pressure test the turbo, IC and any other hoses between them? I can, but don't see why this would make any difference?

[prj]

If it's holding 1 bar like that (with the inlet manifold connected), then it's not a boost leak.

Did you pressurize pre-turbo or post-turbo?

[Sonic]

If it's holding 1 bar like that (with the inlet manifold connected), then it's not a boost leak.

Did you pressurize pre-turbo or post-turbo?

pre-turbo onto the top of the MAF hose where the MAF usually connects.

[prj]

Did you check the breather check valve on the IM?
Block it off, try the car? I mean the small piece where the EVAP connects.