NefMoto

Hey guys, this is the first topic im creating in this forum so im sorry if im wrong in anything, but here we go.

First of all im new to this, my golf is the 1st car i try to modify, I have been following the stage 1 community project with some success, but also a lot of struggles.

They are on Audi, AK file, software 03, im on VW HJ file software 2

I originally copied the diferent maps with WINOLS from an AUQ 032HP file as is the same as mine but 180hp, and i instantly felt a diference in the car, feels better, faster, harder, but i want more.

My car is from 2002 so it has full electronics, and a K03 - 053 turbo (K03S without muffler)
Originally was between 6 to 8 psi depending on the day and temperature, after my change it was boosting 9-10 psi.

So after a lot of reading i started to copy values from the community's project into my file, (i want to keep it that way so i dont have to change any eeprom data)
After all the relevant maps have been copied, the car is even better, boost spikes to 15-16psi and holds 12
i would like to keep the 16psi spike and try to hold 14psi steady untill it drops off to redline

The car feels good and fast, no DTC's .. I also have removed N249 and SAI, but i Kept my PCV and EVAP in, the 2 removed are also coded out on my file, also Rolling pops and bangs, and a Hardcut, car drives with no issue whatsoever.

My main concern is that im doing something wrong as the car is developing somewhat a Hunting Idle, and even tough it pulls fast, it doesnt pull Hard sort of, maybe something with the timing or the fueling isnt right, like when it spikes it pulls fast and hard for 1 or 2 sec, and than it tones down, the speedometer still moves fast, but it feels like the torque dies on me.

After some trouble Logging, (MK4 are known for that) i managed to get some with Me7 Logger in 0x00 Slow mode.

So i will leave my Original File (150hp)
My modified from AUQ (180 Pops and Hardcut)
And my stage 1 V3 with should be close to 200hp
My winols .kp file
with some logs of the stage 1
Everything in the car is AUM stock,
(THIS IS NOT A RATE MY TUNE POST)
I just want more experienced people to take a look at it, and hopefully help me and guide me in the right direction as i do want to learn it properly

Eager to hear back from you guys, hopefully im on the right track

Sorry for double post.. The files are here, when i try to upload them in the OP i was getting timed out

Again im getting timed out im so sorry for triple posting, there seems to be an issue with the file size

Here are the logs and mappack

fueling is off by about 10% on WOT
also you are not anywhere near 200 bhp. I'd bet rather 170
also, you can play a bit with timing.

idle hunting - do you have any kind of cone filter or modified maf? It looks like hfm reading on idle is a bit off.

Stock Filter and Maf
The Car is 100% stock parts, 231000Km
Recently changed timing belt, water pump, did coolant flush, upgraded coolant flanges to aluminium, fixed some vaccum leaks, and thats about it
other than that its all stock.

Fueling 10% off on WOT, by that you mean, its running lean i supose, so i have to enrich it?
Im sorry for the newbness, i am really trying to do this on my own, as i see a lot of people just come here and be like "Stage 1 pls givv" XD

You are out of injector up top end because your request is very rich.
You should do a clean pull from 1500 to redline in the 3rd gear.
your log is not very usefull if you run 2nd gear (low load, very short time) starting above 3000rpm.
Would recomment to log stock file at first to have a base for comparison.

Okay Got it, ill do that and come back to you guys.

Maybe Later as for that i do need to hit the highway once traffic dies down, 3rd gear goes fast, my back road isnt big enough

Double post again, Sorry
I cant add files to my previous post.
I have also tried a friend of mine's tune in my car (copied values)(Same car,same year, same ECU), his does more boost, but again im not hitting my target AFR, why could that happen ? Too much boost ? or not enough injector again ?
and i think the ECU is pulling 2/3 Degrees timing top end due to knock.. also my timing tables didnt change much, where he is running -12 high end, but one thing is for sure, his map on my car feels faster, now my question is, wich one do i refine ??

Here is the Bin and 2 Logs, 1 is 2nd to 3rd gear, the other 3rd gear, but again, not clean log as i ran out of road.. (as in have to brake, the treeline is approaching fast)

You can graph injector duty cycle in ecuxplot.

stop driving like this

One of your logs contains idle at the beginnen. Your lambda control is at 10%. On wot you dont have fuel at all. your lambda control is maxed at 25% all the time. your requested fuel and actual fuel should match. 
You should revert everything back to stock and log again.
check the fuel trims, pressure test everything from the turbo into the combustion chamber or even better smoke test everything with an autel smoke leak device.
Then start with only fuel changes in your tune but dont touch ignition or boost.

After all this you will notice that your fuel pump is weak. Buy a fake dw65v for 100bucks and buy a new fuel filter. Ultrasonic your injectors or just buy new ones.
I dont recommend to buy bigger injectors because this will only create new problems with the software for a novice.

The fuel request in this file looks way more resonable than in your first file. 
You have to learn to read a log with ecuxplot. At 3000 you have 1bar of boost but ecu has to add 20% more fuel because your fuel system cant provide it.
Its a 213000km car  ;)

You refine yours so you actually understand what you're doing.  If AFR doesn't match, sort that first.

Well it turns out my fuel filter was clogged, i put a new one yesterday and the AFR matches now

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Here is a log i did 20min ago, its 3rd gear but it doesnt go to redline. So far AFR is following the desired, and no knock as i dont see any timing retard.

i would like to increase the boost 1 or 2 extra psi, but i have a doubt, if i do that will the ECU compensate for fuel to keep that AFR as long as my fuel system can provide it? if not, what map is responsible for that ? i dont mind the boost tapering down at top end, but id like to increase it in the mid range a bit, but my ijector duty cycle seems linear, is there a way to make it inject more at mid range to go along with the extra boost ?

Before doing anything else, this is the first problem you need to solve.
You need to find a way of doing consistent logs from low RPM to redline.

Until then there is no point to tune anything.

That Log goes from 2000RPM to 5800, The Car doesnt pull anymore after 6000, Im still trying to figure it out, but at 6000 feels like i hit the brakes, So that logs is m Redline technically, I do have Optimal Ingnition angle table retarded to -12000 aroud that area, could that be it ?

WTF did you do that for?

It came in the tune like that, for pops and bangs, but i reverted the timing and ingnition maps to stock, and is still does it, sometimes 5800 sometimes 6000 sometimes 6200, i think im hitting a limit somewhere, it started doing it when i changed some axis for better resolution, the car pulls well and to that point just looses all power at once, i did notice one of the logs the PID went over the roof, i have more logs from today, and ill post the most updated bin later , as im in a christmas party now dont have my laptop here, anyway, im running 14 psi peak atm and 0.84 afr request at wot, the afr is following the requested line well so the fuel filter was the issue, also injector duty cycle is not 100% and not a single degree of timing pull so thats good.
I think i have a problem somewhere else.

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Ign angle goes negative at this range thats why youve lost powr

Its not a loss of power, its a brick wall, feels the same as redline, just lower, on the log, all values just drop straight down intantly, except one PID, i cant remember wich now, i also, i changed my timing and ignition values to stock and it still happens, so thats not it, ill post logs later

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Flash stock map and start from scratch, whatever you have in there now is completely fucked.
Don't flash random tunes.

This is not a hardware issue.

Here is the logs from that run i was talking about.
And the Bin that was on the car..

I will start from scratch, but can anyone take a look, so we can understand what went wrong and not make the same mistake twice ?

As you can see in the log, 3rd Gear, starting at 2000, goes to 5800 and everything just stops, Boost, Fuel, Lambda, straight down, wastegate opens fully .. seems weird to me because in 2nd gear doesnt happen, could it be load related ?

I have the stock file from my ECU, and will start working on that, also reread the 52 page long post on stage 1 community cause i probably missed something.

All help is appreciated

Tomorrow ill log the car on stock file, any other variable i should include in the log ?
Im still using Me7, and not vehical, as it needs internet connection to start, and my cable is a clone and am afraid it gets blacklisted, i dont have a CD drive atm, so im waiting for the stores to open and buy an external CD drive to use the drivers that came with it

Boost pressure below atmospheric
Intake pipe collapsed, try to run without air filter

Im sorry, i was analyzing the log again, everything seems okay, Maf Reading is okay, Maf at throttle plate is a little lower after 5000 wich might mean a boost leak somewhere, injector duty cycle goes only to 95%, temps are fine, no knock, and Bar pressure is constant, i live in belgium, we're 20m above sea level, 1 bar is what we get and that seems constant, at 5800 everything drops, wastegate goes to 100% .. if the charge pipe was colapsing i think the engine would continue to try to inject fuel, keep wastegate closed etc just be starved of air ..

Im gonna go with Pjr on this one, as i really dont think this is an hardware issue either.
Something in the file is fucked. Either a Home Limp, soft cut, something im hitting that it shouldnt, could be due to a Torque Limit, Load Limit im not sure yet, as i need to dig deeper into this, but i do think my charge pipe is fine

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I don't know what you're analyzing. What he told you is clear. Boost pressure below atmospheric with throttle open = TIP collapse. It's that simple, black and white. On your previous log the fucked ignition was the first thing I saw and I didn't look further.
Change inlet pipe and/or air filter. This is a hardware issue, and don't flash random files that create more issues (software issues) to mask it.

Okay i know its been a long time since last post, but the project isnt dead, I ended up using a silicone inlet pipe with a cone air filter, the problem seems to be gone

In the meantime my radiator was leaking so i bought a new one, and silicone coolant hoses, went to replace them and discovered that my front plastic frame was broken, and both my rad, and AC rad were bent, so i went to a junkyard and got a good frame out of another golf, replaced everything, new thermostat, coolant hoses, metal flanges, etc, i also have now a 4 Bar FPR in my garage that i am waiting to install.

I have since than ditched the last tune, i can agree that it was shit, since than i have read and read and read and have been working on something else, i was able to log 232 HP at 5950RPM and 390 NM (ECUxPlot calculation with the constants for MK4), no knock retard, im able to rev all the way to 6800 RPM no problem no cuts no nothing, i have since than also removed the pops and bangs, i Have HardCut but thats about it, it seems tough that i am Maxing out my IDC, thus my AFR goes leaner in the top end, not by much ( from 0.82 to around 0.90 as soon as IDC goes above 100%, the tune is quite agressive and boost is capped at 18 PSI Peak and holding 13 PSI, My Max Timing advance is 24, but i have questions, because the more i read the more confused i get.

I am going to reflash the Stock file again, to calibrate for the 4Bar FPR, and than reapply the changes i have done above to the 4 Bar FPR file.
For my 4 Bar FPR, what exacly needs to be changed ? KRKTE, KVB, do i need to touch TVUB? TEMIN and TEMINVA ?
I want to keep the stock 317cc injectors, but increase the fuel pressure to 4 bar to give me the extra 15% i need not only to maintain AFR but to give some breathing room in case the ecu needs to enrich, At 4 Bar my injectors should be 366cc
Would simply changing KRKTE and KVB be enough ? or do i need the other maps too ?

Edit, i have found multiple calculators, all give me a diferent value, 2 are .exe and it is said in the topic they are not calculating properly, than i have at least 5 excel files, with 2 differences that i noticed, in the constant of n-Heptane, 1 is 0.694g/min and the other is 0.684g/min, wich one do i follow ? i use Shell V-Power RON98 with 5% Ethanol

For me it looks like this and it works ok.

Your stock is the same as mine, 0.10301

So far from the calculators i have a few Possible Values:

0.0921057714946055 with 5% ethanol fuel

0.0890283345582394 from an older 2010 calculator

And Me7TunerWizzard gives me a 0.08941

How is your fuel trims ? I might go with the 0.92

Also was anything else changed ? I know i Need KVB for my MFA to count properly, but what about Tvub Temin and TeminVA ?


EDIT : Alright im going to install the 4 Bar FPR, and tune KRKTE, drive 30km and log my fuel trims, and adjust from there and hopefully that is all i need, on S4 wiki also doesnt mention anything about the other maps just for fuel pressure, also on another topic i was reading say that for FPR i just need to change KRKTE (i hope im not wrong)
Any tips from more experienced members would be helpfull

Okay i have another problem, My Injectors are Bosh 0 280 156 061 .. so far i have found 3 values for the same part number wich are 290cc @ 3Bar , 301cc @3Bar and 316.9cc @ 3Bar ... so wich one is it ? On my stock File KVB is at 316.88 and KRKTE is 0.10311 (not 0.10301 like i preciously said)
Also the correction factor on my definition is 0.000111 and not 0.000167
In the calculator if i calculate from my stock KRKTE with a factor of 0.00001667 and value of 317cc it gives me a very close to stock value but if i change the formula to 0.0000111 than my KRKTE for stock comes up around 0.15xxxx .. in Winols is the other way around, Factor of 0.000111 is 0.103xxx and factor of 0.000167 is 0.15xxxx .. i am so confused right now 

Im guessing they are effectively 317cc injectors, but there is too much contradiction in the data that im finding

My Ecu Cpu is a Siemens C167CR  .. what clock speed does it run?

If KVB is 317 and you have a 3 bar FPR then the injectors are 317cc/min @ 3 bar.

but you're driving through all this, just release the injectors, you don't change the pressure, so just click. kvb if you have a consumption counter on the clock. You enter my value and check if it is OK, if it is not correct, correct it.