Wastegate spring mod

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  • newsh
    S2Forum Obsessed
    • Aug 2003
    • 16226
    • Country: United Kingdom

    #1

    Wastegate spring mod

    I'm sure Mihnea will have something to say about this but here goes

    After the RR weekend, finding the problems with my car, getting the WGFV working and curing the misfire I was finally able to get the full 20 psi of boost that the Mihnea-Homefry remap was designed to give. In addition to this I could see from my boost gauge that if the pedal was floored at say 3000 rpm I would get a few, 2 or 3 lbs of extra boost before the boost dropped back to 20lbs.
    I hooted and cackled to myself at the fun of all this and ripped around the local countyside gleefully for a week or so at all times of day and night burning large quantities of fresh Optimax and generally abusing my tyres, transmission and the local council's finest tarmac products..

    What was odd though was that the car felt really flat for most of the throttle travel, boosting only to 8 or 10 lbs then in the last inch of travel the boost would snap up to 20 odd. Exciting but not terribly drivable. Over the years of driving my various Audis, all with mechanical boost control, K-Jet systems) I've got used to being able modulate the boost with my foot and this on-off sudden burst of power felt strange to me. I got some improvement by screwing the WG spring down a few turns but the boost still didn't seem to ramp up with throttle to the point where the Electronics comes in and takes over from the spring..

    So I decided to try going back to the stronger WR type spring that was in my WG when I fitted it and which allowed around 15lbs of mechanically controlled boost with the WGFV not operating. I tried it out this afternoon and I'm well pleased with the results. Firstly I backed off the spring adjust almost all the way to the top, about 10mm down and took a run up the road. Instantly the car pulled much harder at part throttle and felt more torquey and drivable but when the electronics took over the boost slammed up to almost 30lbs which was a bit scary. Backing off the spring another few turns brought the couple of seconds or so of overboost back down to 25 or 26 lbs and the boost then drops to 20lbs, gradually fading above 4500 ish rpm.
    So the car is driving much more how I'd like it to be, though I suppose I'm wondering:

    Is it still safe??
    Or is it going to blow up??


    Oh yeah and I think I've cooked my clutch
    Last edited by newsh; 1 January 2004, 12:05.

    S2 Coupe 3B Project


    Ur quattro restoration

    S2 Avant

    Boost is the new rock and roll!
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  • S2 Ant
    S2Forum Possessed
    • Jul 2003
    • 3682
    • Country: United Kingdom

    #2
    Sounds phat! havent a clue bout ur engine tho LOL
    Ant

    2007 Mk5 Golf GTi, 3 door, DSG, REVO Stg 2 and other goodies
    2011 Kawasaki Z1000

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    • SteveH
      Super Moderator
      • Jul 2003
      • 4460
      • Country: United Kingdom

      #3
      Sounds like you were experiencing a bit of wastegate creep with the old spring. The added boost from the re-map probably made it more evident. Mihnea can supply a heavier WG spring for high boost motors. Mind, these are like suspension springs
      91 Modded 3B
      14 A6 Avant Black Edition

      Comment

      • newsh
        S2Forum Obsessed
        • Aug 2003
        • 16226
        • Country: United Kingdom

        #4
        The one I had in there was a stock S2 spring given to me by Mihnea to try when I was fault finding my car. The one I have in now is, I believe, a stock ur quattro spring. I also have another even stronger spring which was in there when I was struggling to get boost and was responsible for a few seconds of 2bar boost when I finally I got the WGFV working.:eek2:

        They are, left to right,

        Stock S2 ----- UR ----- Even stronger!
        Attached Files

        S2 Coupe 3B Project


        Ur quattro restoration

        S2 Avant

        Boost is the new rock and roll!
        sigpic

        Comment

        • newsh
          S2Forum Obsessed
          • Aug 2003
          • 16226
          • Country: United Kingdom

          #5
          @ Mihnea

          Any comments?

          When are you over next?
          Last edited by newsh; 1 January 2004, 12:07.

          S2 Coupe 3B Project


          Ur quattro restoration

          S2 Avant

          Boost is the new rock and roll!
          sigpic

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          • newsh
            S2Forum Obsessed
            • Aug 2003
            • 16226
            • Country: United Kingdom

            #6
            The new clutch is going in today with an uprated pressure plate, Hurrah!

            I'll now be able to keep my foot on the loud pedal...

            S2 Coupe 3B Project


            Ur quattro restoration

            S2 Avant

            Boost is the new rock and roll!
            sigpic

            Comment

            • Mihnea
              S2Forum Extremist
              • Jul 2003
              • 1288
              • Home: Belgium Current: United Kingdom

              #7
              John,


              I think I'll be there next around February or thereabouts...

              However, even 25 psi is a bit too much for a stock turbo, especially for yours, because it already has 200k on the clock....

              If it starts whistling soon, don't worry, that will be your turbo on its way out

              The problem is that I've figured as well that the 3B boost control is a bit weird and doesn't let you have much boost at part throttle, whereas the ABY one does....

              I think your boost chip would require real-time remapping so you don't exceed the maximum safe boost levels with that big spring while still being able to get boost at part throttle....


              Cheers,

              Mihnea
              '98 Silver Grey 2.7T S4, dual 2.75" turbo back exhaust with no cats, FMIC, BIG injectors, 10 Bar motorsport fuel pump, modded RS4 turbos, tubular exhaust manifolds, custom intakes, RS4 MAF, Bilstein PSS9, H&R ARBs, 19" BBS CH, custom remap, 511 BHP/505ft-lbs

              www.MRCTuning.com
              info@MRCTuning.com
              Workshop Directions

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              • newsh
                S2Forum Obsessed
                • Aug 2003
                • 16226
                • Country: United Kingdom

                #8
                Originally posted by Mihnea
                John,

                I think your boost chip would require real-time remapping so you don't exceed the maximum safe boost levels with that big spring while still being able to get boost at part throttle....

                Cheers,

                Mihnea

                Thanks for the reply.

                Understood, I'll take it easy and look forward to your next visit.

                I've been thinking about a k26 with a hybrid cold side like I have on the ur... I'll try to find out exactly what the spec is, it's supposed to be good for 2bar or more.

                S2 Coupe 3B Project


                Ur quattro restoration

                S2 Avant

                Boost is the new rock and roll!
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