after RS2+ upgrade, Fault Code 00519 and Boost fluctuating / going limp mode.

[Foeglass]

Hey everyone,

I've recently done a RS2+ upgrade.
I got the following parts installed all are brand new.

RS2 turbo, new and genuine.
WAGNER RS2 evo exhaust manifold,
WAGNER RS2 evo intercooler,
RS2 green injectors
Bosch 044 fuelpump relais powered.
3 inch downpipe wich smootly goes down to 2,75 inch at the middle.
2,75 catless exhaust (middle muffler / endmuffler)
Forge DV007
2.0 TFSI single ignition coils conversion.
Refurbished wastegate.
new N75 wgfv. valve.
Paul Nugent RS2 homefry chipset, 3 bar MAP and transistormod. on stock 4 bar FPR.


Now after installing everything and going for a first test drive first warming up. and than test out the new power!
started with 50% throttle immeditatly felt the car pulling hard around 3000RPM faster than it was stock!
than i had to stop at a junction and shifted up to third around 2500 rpm and gave full throttle slowly not abrupt.

But than not what i expected...
it had stock power unfortunatly. went limp mode and boost didnt get over 0,6 bar. headed home covered the faultcodes:
it gave an 00519 - intake manifold pressure G71 - 06-00 - Signal too high..

i removed the fault and started the car, no errors. - i than gave some revs and let it idle a few times.
it than again popped up the sam error 00519.

i had a look at the vaccumline between ecu and intake. al was good. also the line inside the ecu was still good. not blocked or any leakage.
after 15 min i started the car up again again gave it some throttle / idle. this time no codes..

So took her for a test drive again and gave full throttle this time the car went like a rocket!
i got to drive around for with good power..
than i went for a cooling down, turned around at a junction again and gave some throttle and again limp mode and 0,6 bar..

Again the error, 00519 - intake manifold pressure G71 - 06-00 - Signal too high..

The car now sometimes goes immidiatly in limpmode without even asking for power.
when it doesnt limp. the power is very fluctuating. boost levels go from 0,8 bar to 1,9 and keeps swinging all over.. never gets stable.


I was wondering if anyone has ever experienced this before or might have a lead on where to where to look for?

never had any issues with the car before the conversion.

Thanks in advance!.

Cheers, Tom.

[UrS4boy]

00519 Code (blink code 2222)

•2222 (Blink Fault Code), 00519 VAG1551/2 Fault Code Number
ECU Internal Pressure sensor (G71)
Pressure sensor defective,
Repair or replace ECU or replace internal pressure sensor

The fact that after you get the check engine light you only have 0.6 Bar indicates that the ECU is not controlling the N75 Wastegate Frequency Valve to provide more boost. The ECU can only control the N75 if it gets feed back from the G71 MAP sensor. This, with the 00519 code, implies to me that your ECU has an issue with the MAP sensor, potentially because it wasn't installed properly (poor electrical connections) or the MAP sensor is not compatible with the ECU. Needs more investigation and details about the MAP sensor IMO.

G71 MAP sensor info: http://forums.quattroworld.com/s4s6/msgs/20417.phtml

N75 WGFV info: http://forums.quattroworld.com/s4s6/msgs/20987.phtml

[Foeglass]

Thanks for your reply,
I dont get an engine check light. it just goes into limp mode.
and it sometimes goes into limp mode right after startup. while at other times it doesnt and boost comes in good, but than starts to fluctuate / going all over the place you can feel the boost building up and letting go. building up and letting go. in second and third gear its noticeable but offcourse in 4,5 and 6 gear the effect gets stronger.

The MAP sensor and chipset are from Paul Nugent (S2central - here in S2forum)
So i think we can safely say that its not an issue between the chipset and the MAP sensor since there are more people on this forum driving around on his software.
The map sensor is installed properly soldering is good. its been checked twice allready.
But perhaps the map sensor isnt functioning well?


i've got two video's we made of the boostgauge. the gauge may not be accurate but thats not the point its just to point out the boost fluctuations.
both videos were not with full throttle. i gave her around 75% throttle.

Here you can see how the boost shifts around all over the place...

http://www.youtube.com/watch?v=L86ETOHoS_M

http://www.youtube.com/watch?v=2oVrJvFfEDE

00519
Intake manifold
pressure sender G71

-Signal too small
-Signal too large
-Control difference

-Vacuum line from intake manifold
to J220 interrupted, blocked, kinked
or crimped
-Liquid seperator in hose line from intake
manifold to J220 full of liquid
-Blow off valve faulty
-Solenoid valve for boost pressure limiter
N75 faulty
-Pressure sensor in Motronic control unit
J220 faulty
-Turbocharger faulty

Thats what it says on http://www.s2-audi.co.uk/tech_articl...ecu_faults.htm

[220bhp]

Get a proper map before its to late. BTDT

[simon20vq]

Have you fitted the N75 the wrong way around?

[Foeglass]

Get a proper map before its to late. BTDT

Can you please explain that a bit more?

I got the RS2 V-stream chipset from Paul Nugent everywhere on this forum his chipsets are proven to be good. so thats why i got my ecu over to him.

And now you say i have to get a proper map?


The N75 is still mounted the same way before i had the RS2 parts installed and the car drove flawless and good with standard S2 software/hardware.

[prj]

From your boost gauge, it is hitting boost cut, but not cutting fast enough.
I saw more than 2.3 bar on the gauge.
Thus also your fault code, because most likely the MAP sensor is 300kpa.

If you continue doing this over and over, you can soon look at the rods through the block. In fact, if they are stock, they might be bent already.

[Foeglass]

I am not continuing doing this. hence the reason i didnt gave it full throttle. or just gave it WOT instantly.
I want to solve this issue first before i drive the car any further or gonna push it.

The engine still runs smooth without any hickups or balance issues. i am positive the rods are ok, i also opted for the "save" chipset wich limits the torque as i understood.

Yes the MAP sensor is a 300Kpa.
But does noone have any idea in wich direction i can search?
Or is this really a software / map sensore issue?

[prj]

The engine still runs smooth without any hickups or balance issues. i am positive the rods are ok

And you know this without dropping the sump? Or removing the plugs and checking the depth of the hole at TDC on each piston? Do you have x-ray vision?

i also opted for the "save" chipset wich limits the torque as i understood.

Well clearly nothing is being limited when it's boosting 2.3 bar.

What spring do you have in the WG, is it stock?

[Henkjan]

The N75 is still mounted the same way before i had the RS2 parts installed and the car drove flawless and good with standard S2 software/hardware.

did you remove it during the build? if so, please double check, because what you discribe sounds a lot like what I had when I made an with the N75

[Foeglass]

And you know this without dropping the sump? Or removing the plugs and checking the depth of the hole at TDC on each piston? Do you have x-ray vision?

Well clearly nothing is being limited when it's boosting 2.3 bar.

What spring do you have in the WG, is it stock?

No i dont have x-ray vision, and my wg spring is stock. set to 0,6 bar.
Thanks for your reply.

Henk-Jan: i didnt remove the N75 i left it on. but i will double check it again. thanks for your suggestion!

[prj]

Stock is 0.4 bar, 0.6 bar is not stock.
The spring also should not be wound down in any way from the screw in the wastegate cap, it should be about 7-8mm below the "flush" line.

Also, how is it possible that you list "New N75 Valve", but you did not remove it?

[Foeglass]

Why the attitute if i may ask? i didnt knew i was on trial here PRJ.
im only asking for advice / help on my problem.
if you dont want to give me any, than please dont reply.

if i sayd something to dishonor you by any way, than my appologies..

Good than my wastegate isnt set properly. thanks for pointing that out.
i searched on different forums and one sayd 0,4 others sayd 0,6 so i went with 0,6.
i will readjust the waste properly. again thanks for pointing out.

The N75 valve was installed last month with the original S2 turbo,
Not because it was broken but just because i wanted those parts to be new. for my own good feeling.
also the Intercooler and fuelpump, Forge valve were installed earlyer.
same goes for the ignition, ect ect. i also installed that before i did the RS2 turbo conversion.
i did everything in stages.

all due to the fact that if something goes wrong / a eroor comes up i can more easely spot the problem.. thats why i installed everything in different stages.

The Turbo and exhaust ect were also driven with the original software and injectors.

This problem came up after i installed the injectors and the modded ECU. wich was the final step.

I hope i have explained verything clearly now.

[prj]

Nothing to do with a trial, it's just some of your statements go against each other.

Clearly, if your car was in perfect condition, then everything should run perfect.
Yet it doesn't, so things have to be clarified, especially if what you say seems contradictory. We only have the info to go on which you state in the first post, not anymore - as you keep adding more information the picture becomes more clear.

Having the wastegate set to 0.6 bar with that chipset (which btw, severely limits spring travel with the stock spring, as it must be wound way down) can be the source of your issues.
While the stock setup will operate with a locked wastegate for prolonged periods of time, the RS2 turbo is a bit bigger and enough to blow up your engine should it be run with a locked wastegate.

I was not kidding about the rods being bent btw, If I were you I'd pull the plugs, carefully bring each cylinder to TDC and measure the depth from the plug hole, then make sure it is uniform across the cylinders.

Btw, every single thing I stated was cold hard fact. You don't have to like it though...

[Ross]

That's some nasty overboosting - assuming the ECU is not requesting that much boost, and the MAP sensor is good, and it doesn't have a 2.3bar spring in the WG there's only really two logical scenario's:

1) The ECU is not seeing the boost signal - vac line disconnected, or kinked
2) The WG is not responding to a reuest to open - WG stuck closed or WGFV not functioning correctly

I would say you can ignore 1) - your getting a boost gauge signal which i assume is connceted to the ECU line near the ECU, and if it wasn't getting a signal it wouldn't be cutting boost which it appears to be doing, because it wouldn't be aware

So check the WGFV is getting a signal and fucntioning correctly - new or not - Sonic had boost issues for a while, turned out to be a bad (new) WGFV). Also double check plumbing. If the WG was getting stuck you'd expect it to overboost in limp mode too so really everything is pointing to the WGFV.