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

[newsh]

I guess the other possibility is a small leak in the N75 pipework,

[Foeglass]

Wish i would have known that earlyer..

I dont think i'm going to keep this software. i'd rather have software that does work with a boostcut and all the other factory's safety features.

I'm not aiming for max HP and Torque, if it runs 350ish hp and is safe and fun to drive ill be ok with that i'd rather have that than running something on the edge.

But that doesnt solve the problem. the car should be able to run good with this software. and as of now it doesnt.

I will test the car first with the other boostgauge and N75 valve disconnected.
will let you know that goes! Thanks again.

[220bhp]

Wish i would have known that earlyer..

I dont think i'm going to keep this software. i'd rather have software that does work with a boostcut and all the other factory's safety features.

I'm not aiming for max HP and Torque, if it runs 350ish hp and is safe and fun to drive ill be ok with that i'd rather have that than running something on the edge.

But that doesnt solve the problem. the car should be able to run good with this software. and as of now it doesnt.

I will test the car first with the other boostgauge and N75 valve disconnected.
will let you know that goes! Thanks again.

[newsh]

Have you done a boost leak test? Sorry if this has already been mentioned.

[Foeglass]

I've installed a new N75 valve this weekend, and took the S2 for a spin.
At first it all seemed well when i now gave part throttle the boost was regulated nicely at 1,5 bar if i gave more thorttle the boost would go up untill 1,7 (i didnt gave WOT! )
i turned around at the end of the road and in fourth gear slowly gave began to give WOT, boost builded up nicely untill 2,1 bar i than lifted of the throttle to avoid getting higher boost, than again gave more throttle and the whole problem started all over again, boost fluctuation all over from 1,2 bar to 1,8 bar...

But no codes came up this time....

The Wastegate and all N75 plumbing have been tested on 2,5 bar.

I have performed a boostleak test from turbo exit hose untill the black pipe that runs next to the valve cover.
The rubber hose at the Throttle body ive examined for cracks, it al looked good.

Injector seals are new and went in tight, so i cant image those would leak?

im kinda running out of ideas.. can i safely put back my chipped S2 software even with the 300Kpa map sensor and the resistormod R201? to see how the car performs than?

[prj]

Do you intentionally ignore the advice about the wastegate spring?
If the spring is not set to 0.4 this software will never control boost properly, end of.

I have performed a boostleak test from turbo exit hose untill the black pipe that runs next to the valve cover.

Was the IM connected when you pressure tested it?
The PCV you should never connect when doing a pressure test.

[UrS4boy]

...I have performed a boostleak test from turbo exit hose untill the black pipe that runs next to the valve cover. The rubber hose at the Throttle body ive examined for cracks, it al looked good. Injector seals are new and went in tight, so i cant image those would leak?

That's not a proper boost leak test. You are missing a bunch of stuff that can potentially cause a leak if that is all you do. As Robin (twoqu) has said, there are many possibilities for boost leaks, not just in the turbo to intake manifold tract but also in the various PCV and evaporative emissions pipes and hoses if things go bad.

As per his (and prj's) suggestion, to capture all the potential leaks at once, you place the pressure bung in position A1 and you disconnect and plug A3 in the diagram below. If you pressurize to 1 Bar, that should be enough to find a leak.

More boost leak testing info: http://www.s2forum.com/forum/showthr...538#post709538

[Foeglass]

Do you intentionally ignore the advice about the wastegate spring?
If the spring is not set to 0.4 this software will never control boost properly, end of.


Was the IM connected when you pressure tested it?
The PCV you should never connect when doing a pressure test.

Ah no PRJ, i forgot to mension that, I just have little time sometimes and reply fast.
i forget things my apologies.

I have a new boostgauge now, And i have performed a WOT run with the N75 diconnected!
Boost levels kept nicely 0,4 bar slightly going down to 0.35? high in the revs..

And as i was just pointed out by URS4boy i've done the boost test completly wrong.

Thanks for the diagram! i will also go through your topic and read it through.

Again thanks for awnsers and help everyone!

[twoqu]

I also have a horrible feeling that there are 2 versions of that SW. One is for S2 without the resistor mod and one is for the RS2 which of course already has the resistor. What happens when you use the S2 based one in what is effectively an RS2 ecu I am not sure. Perhaps PRJ can expalin.
Not sure how you could tell which one you have without perhaps getting the files read and examined by someone who knew what to look for. One solution might be to source some standard RS2 chips to run on your ecu and see how the car performs. If it works as it should then its a SW issue. Of course you could just source some proven SW!

[prj]

I also have a horrible feeling that there are 2 versions of that SW. One is for S2 without the resistor mod and one is for the RS2 which of course already has the resistor. What happens when you use the S2 based one in what is effectively an RS2 ecu I am not sure. Perhaps PRJ can expalin.

Not an issue here ... and it's not going to cause boost issues.

If WG spring is 0.4 bar then this should "just work".
Check your wastegate membrane and make sure it does not have any holes in it.
If you do a boost leak test properly - insert bung instead of MAF and blank off PCV hole in maf->turbo hose, then it should highlight this too.

[220bhp]

Do you have a chipped RS2 ecu or an s2 ecu with rs2 chips