ECU boost leak & a trip to MRC!

[Jamo]

Just come back from MRC today, Doug has sorted the car out a right treat.

Will post pictures up later with more of a write up.

[terrybullwon]

good stuff bet she shifts now :mischeif:

[alg]

Just come back from MRC today, Doug has sorted the car out a right treat.

Will post pictures up later with more of a write up.

No one told me that MRC did 'boost controllers'. Guess it will turn up to 11 now

[Jamo]

Day trip to MRC

Today i had an emergency appointment booked with MRC to check my car over so that I can start from a good base for the rest of my ownership.

Part 1)

The car was pressure tested to see if it could hold boost.

On pressurising two leaks were established a) ECU b) Intercooler.

The intercooler had a perfect pin-hole in the bottom of it. This was very freaky, hole looked like it had been drilled!

A quick pit-stop to an MRC contact and the intercooler hole was welded and repaired back to factory standard

[Jamo]

Part II - The ECU

The ECU was opened and the chips read

Mihnea diagnositic of the cars chip -

Stock RS2 fueling, no timing advance, incorrect chip checksum hence why i was seeing control unit defective in my vag-com sessions.

On opening of the ECU it was obvious why it was leaking.

Spot the MAP sensor anyone?

[Jamo]

ECU - Part 3

After a bit soldering and digging around a 2.5 Kpa was installed into the ECU.

For a future upgrade a 3 Kpa sensor is required so that my car can run more than 1.5 bar boost but for now needs must.

[Rusty]

Phook Jamo

That's not great but LMAO at the "Emperor's new MAP sensor!!!"

What's the beast like now then... ???

[Jamo]

Part 4 - Putting it back together.

This is where the fun began, my lambda probe in my car had to be removed to put a wideband O2 sensor in the car plus it was due to be replaced with a new part.

Would the existing probe come out? Would it heck! It took a serious amount of muscle power from 3 different people to finally remove the probe!

On examination the old probe had no thread it looked like it had been hammered into the downpipe.

The downpipe was retapped so that the new one would go in without a problem.

[Jamo]

The Mapping -

The car was returned to stock configuration and the boost pipes returned to the WGFV.

After some serious trial and error sessions due to the unique configuration of my cars engine the car was mapped to run 1.45 boost getting excellent AFR and EGT values.

Doug believes the car can be pushed more than was possible (due to the 2.5 Kpa MAP sensor) as the EGT's were only around 750-750 C when pushed hard and the turbo is capable of making alot more boost.

Conclusion?

The car is allot smoother, the idle has been move to 800 rpm for the moment to cover the 7A inlet cam although this probably go back to stock value IMO long term.

Next step is more boost with the 3Kpa MAP sensor bring it on

Big thanks to MRC for giving my car a sound base to progress to my cars full potential and really pulling out the stops in getting it back to a good state.

Can highly recommend them for any S2 work. Whilst there viewed a couple of customers car, a tasty S4, RS4, VW 1.8T MK4 show car ( as seen in this months VW performance magazine ) and a S3. MRC are really playing the VAG field

The drive home was like silk, very smooth, instant response and most of all I feel confident of the cars current configuation.

Next stop is Western Performance for another RR session to find out what stage the car is at.


Moderators Note:

Although disconnected the advantages of the boost controller can be seen as full boost is only available at WOT via the ECU where it was available at part throttle with the boost controller which does make the car seem slower as the driver has to be more aggressive to get full boost BUT now the car is back to stock configuraiton all safety protocols are back inplace and the car really does drive like a dream.

[Rusty]

Glad the effects of bad Rice are all sorted mate .

Only problem now is that we'll have to find someone else to give a good ribbing to at the next RR session!!!

Maybe I'll rig up some water injection or something equally controversial.

[terrybullwon]

What power does the bottom dyno pridict???

[Jamo]

I have water injection, and who said you've seen the last of the boost controller? :mischeif:

Hehehe

[Jamo]

What power does the bottom dyno pridict???

No idea, i'm not predicting anything to be honest just going to see where it's at.

[Ross]

What was vMAX on the Banbury hill-climb? In secret units of course

Does the car feel faster?

I saw 1.52units indicated

[Ross]

PS Jamo delete some PM's!!