Boost Leak!

[stevieyid]

Ill get the vac lines checked with newsh soon hopefully. Could a little leak from the intercooler like that cause problems with the boost such as i described?

[dest]

ANY boost leak can and will cause problems!
I had a very small hole in the back of the intercooler and it caused big problems with boost cut

[stevieyid]

Well ill get it blocked up somehow! I unscrewed the nipple but any bolt i try and put in there just wont tighten enough. Looks like i might have to get it welded.

[newsh]

can you not fit a bit of tube to the nipple??

[dest]

Or use some PTFE tape on the bolt?

[stevieyid]

Sorry what PTFE tape and will it hold a good enough bond? The nipple is very small so it would be hard to attach anything on it. Anyone able to weld it up in the south east area? Ill take the intercooler off the car and bring it to you.

[newsh]

take the nipple into your local plumbers suppliers, they may well have a blanking plug the right thread, it will prob be unc or gas thread. Rose Autos in Crawley, near Halfords would be a good place to try too.

[newsh]

Or bring the nipple to me and I'll drill and tap it and blank it off with a small bolt and loctite

No need to take the IC off

[stevieyid]

John Brillitant thanks. Ill come over. I sent you a pm did u get it?

[newsh]

Yep, reply sent

[S2central.net]

And was the nipple surgery successful ?

[stevieyid]

Aelred came round today to check everything over and everything looks fine. The nipple has been sorted and no leaks, but still having the same boosting issues. If i rev the car through its rev range in first, second and third the cars boost fine and goes like a train. If i give it WOT from low revs in third it boosts to full boost then drops to 5 psi then sets off again to the red line! Any advice on what this could be? Get a squeeling noise that aelred thinks is from the induction system. I have tried my brothers K&N and Maf and no change, so any other ideas?

[S2central.net]

When does the boost cut happen - at what rpm - and does it give any fault codes ?

Only doubt I have is the ECU behaviour with the RS2+ boost chip that I rescaled for the 2.5bar MAP sensor. Yours was first for that treatment and there is a chance some bug exists with that at max boost in high gears. I'm getting some 3bar MAPs in next week so I can tweak your ECU again to remove that variable... meantime, if you can swap ECUs with another RS2 runner that would be a good comparison test - see if the badness stays with the car or moves with the ECU.

[stevieyid]

it happens around 4k rpm. I dont have vag com yet so im not sure if it is throwing any codes out. I cant get hold of another ecu with the right chips. My brothers one is currently mapped to run with normal injectors as he is yet to complete the conversion

[S2central.net]

Any RS2 ECU will do... I have the 3bar MAPs ordered - no extra charge to you and I'll remove that variable.