Mr Simmonds 3B lite project.

[K Simmonds]

I need a pair of Mk2 backrests like that, I have the bench but my backrests are Mk1

You post whilst I was just typing the info above.

Yeah I though that was about all the TPS did.

I ended up picking up a complete late ABY interior (thanks Dubmanted) in the end to get the complete rear bench set, it was a fair amount of hassle but I managed to sell the spare fronts for more than I paid for them plus I got a much better set of door cards out of the deal. Funnily enough my old half leather interior and door cards were collected yesterday, glad to have got that out the way, got somewhere to keep my 17" wheels/tyres in the dark now.

[andy10v]

Its great if its working, I just don't understand how.

If the injectors are maxxed at 1.9 bar at 4 bar base pressure, I don't understand how then can still provide enough fuel for 1.9 bar at 3 bar base fuel pressure.

I might cautiously try and let you know how it goes.

I wonder what duty cycle people normally run, eg if they are at 80% on a 4 bar fpr and 1.9 bar of boost, would 100% duty cycle on a 3 bar work?

I will have a play about with an injector calculator tonight and see what flow at pressure etc.

[andy10v]

What needs more fuel, 1.9 bar at 3500, or 1.5 bar at 7000? Or irrelevant silly question?

[K Simmonds]

I don't know either mate, anyway thanks for you input, in the mean time I'm not going to give the car too much stick.

I may even put the 4 bar FPR back on just to be completely safe.

As you say I can't really see how RS2 injectors could provide enough fuel at 3 bar for 1.9 bar of boost with an RS2 turbo.

[kibby]

ive checked my fpr its a 4 bar unit my car was awesome low down torque was ballistic , as you say awesome for overtaking considering my car is a tad lighter than a s2.
I'd rather run slightly rich than lean always averaged good mpg on long runs

[K Simmonds]

ive checked my fpr its a 4 bar unit my car was awesome low down torque was ballistic , as you say awesome for overtaking considering my car is a tad lighter than a s2.
I'd rather run slightly rich than lean always averaged good mpg on long runs

Thanks for taking the time to check and for your input mate

Right I'll put the 4 bar one back on and try and work out what's causing the over enrichment on WOT.

My car is a fair bit lighter than stock (1350kg) so I don't expect there's that much difference in weight.

And yep, the low down torque is quite something, I love the set up.

I think I'll get my injectors serviced as the next measure.

[andy10v]

ive checked my fpr its a 4 bar unit my car was awesome low down torque was ballistic , as you say awesome for overtaking considering my car is a tad lighter than a s2.
I'd rather run slightly rich than lean always averaged good mpg on long runs

Did PRJ map this chipset on your car before you changed to COP? Or is this the chipset Hoffer fitted?

[K Simmonds]

I'm pretty sure he mentioned that PRJ fitted the 3 bar map sensor to this ECU and the maps were his but I'll let Kibby confirm whether that's the case or not.

I pulled the codes again this evening, got the following.

Address 01: Engine Labels: Redir Fail!
Control Module Part Number: 857 907 404 B
Component and/or Version: MOTOR PMC 1
Software Coding: 0261200453
Work Shop Code: 1267356261
VCID: 1E39DDF29A73A9EE89B-4B00
4 Faults Found:

00516 - Closed Throttle (Idle) Position Switch (F60)
30-10 - Open or Short to Plus - Intermittent
65535 - Internal Control Module Memory Error
00-00 - -
00532 - Supply Voltage B+
07-10 - Signal too Low - Intermittent
00513 - Engine Speed Sensor (G28)
03-00 - No Signal

I know why Supply Voltage B+ is there, the voltage regulator died on the alternator last week and I had to drive a few miles on the battery, I'm guess this could also explain the Internal Control Module Memory Error.

Closed Throttle (Idle) Position Switch (F60) is the one that popped up in the summer, I adjusted the throttle stop and hadn't seen it since. I had one of Nip super sexy throttle body cams arrive today, very nicely made, will fit that to my spare throttle body tomorrow morning and swap it on to the car. Will pop the 7A FPR back on again, clear the codes, boost leak test yet again just for fun and go from there.

[kibby]

It was a chipset supplied and fitted by hoffer

[andy10v]

ADU

360 cc/ min @ 3.0 bar
405 cc/ min @ 3.8 bar
416 cc/ min @ 4.0 bar
465 cc/ min @ 5.0 bar

3B
320 cc/ min @ 3.0 bar

ABY/AAN
320cc/ Min @ 4.0 bar

From an ABY running s2central 1.9/1.5 chipset

Injectors are maxed, yeah.
The formula is (IPW+Lagtime)*RPM/1200 when using values from VAG-COM.
This is because Motronic outputs the desired actual injector opening time to VAG-COM, without taking lag time into account, which it adds later.
The lag time for RS2 injectors at 13.25 volts is 0.58ms (as it is set in the Motronic ECU).

Here is the output from your car with the injector duty cycle added:

RPM	Inj. On Time	IDC	Voltage
			
 /min	 ms	%	 V
720	2.21	1.67	13,74
680	2.47	1.73	13,60
760	2.34	1.85	13,74
720	2.34	1.75	13,74
720	2.34	1.75	13,74
720	2.34	1.75	13,53
720	2.21	1.67	13,80
760	2.34	1.85	13,67
840	7.02	5.32	14,01
1720	3.9	6.42	13,74
1600	4.29	6.49	13,74
1480	4.94	6.81	13,46
2120	5.72	11.13	13,74
2880	6.24	16.37	13,67
3720	5.85	19.93	13,74
3360	1.04	4.54	13,46
2440	5.59	12.55	13,74
2480	6.5	14.63	13,74
2800	7.02	17.73	13,67
3200	7.93	22.69	13,74
3640	10.92	34.88	13,60
4280	12.61	47.04	13,46
5000	20.67	88.54	13,40
6000	18.07	93.25	13,33
7080	16.25	99.30	13,33
5720	8.71	44.28	13,40
5440	19.63	91.62	13,33
5880	18.59	93.93	13,26
6320	17.42	94.80	13,26
6760	16.25	94.81	13,46
6400	1.04	8.64	13,74
5560	15.34	73.76	13,40
5760	18.85	93.26	13,40
5960	18.2	93.27	13,40
5480	1.04	7.40	13,67

That's why I keep telling people RS2 injectors are too small
Running anything over 90% is generally a bad idea, because if for any reason at all there is a boost spike, there won't be enough fuel.
Also, there is not enough injector room here for any knock enrichment. If you knock, it will just flatline and keep knocking.

Using a calculator to set RS2 injectors to make 360bhp, then using everything the same but dropping the fuel pressure (Note 100% DC, and optimistic BSFC to make the numbers work with "known" bhp for the 360bhp RS2)

[andy10v]

Has anybody ever heard of a 3B being mapped with a 3.8 bar FPR? (eg to more genuinely replicate and RS2 setup for some reason?)

[K Simmonds]

It was a chipset supplied and fitted by hoffer

Thanks for clearing that that up

Off to edit my sig.

[andy10v]

lol

I could also understand a 3b being mapped conservatively on a 3bar fpr, but not that much boost?

Unless it is just a safe/rich chipset?

[K Simmonds]

Nice one for taking the time to find that info Andy, much appreciated,

I agree that much boost requires a 4 bar FPR with RS2 injectors, the car goes very well with either regulator fitted but was certainly a bit too rich with the 4 bar one. I'll put it back on along with swapping the the throttle body/TPS and see what happens.

[andy10v]

Why does the car not go crazy lean with a 3 bar fpr?