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Author Topic: 1.8T k04 hybrid boost increase issues  (Read 100016 times)
azaiats
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« Reply #120 on: May 05, 2012, 10:16:10 AM »

Any more news? Smiley
Did you get the car to a dyno or something that can measure your results?

My car is getting a k04/e05 this week and I want to make some improvements by myself, like you did. Nothing but just the k04/e05 and a 4bar FPR that I'm planning to use.

Nice thread by the way. Thanks for all contributors.
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2003 1.8T AUQ @ 06A906032HP - k04/e05 20psi - 317cc @ 4.5fpr - K&N @ stock box - ceramic clutch - 18" tsw wheels @ yoko's 235/45/18 @ eibach lowered springs

deka's 870cc in on the way down... boost wait for me Wink
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« Reply #121 on: May 06, 2012, 11:27:24 PM »

havent had a chance to put it on the dyno but the car has been flying! easily beats modded 2.0T love the surge of power and the noise from the DV.
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azaiats
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« Reply #122 on: May 11, 2012, 02:37:08 PM »

artite: when you first swapped the turbo and installed the k04, your car runs fine with k03 software?

Just picked up my car today and it's seems a bit weird. After 3000+ rpm the car seems to lose boost... acting like if I released the accelerator and I can hear the blowoff valve sending boost to intake again... but I'm WOT, which seems a lot weird. I read something about this can be "limp mode" because k04 is overboosting.

This can be fixed with ECU mapping or I'll need to trick my MAP with some kind of diode? Anybody have a clue on this?
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2003 1.8T AUQ @ 06A906032HP - k04/e05 20psi - 317cc @ 4.5fpr - K&N @ stock box - ceramic clutch - 18" tsw wheels @ yoko's 235/45/18 @ eibach lowered springs

deka's 870cc in on the way down... boost wait for me Wink
airtite
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« Reply #123 on: May 12, 2012, 12:49:51 AM »

if you are running stock software then you shouldnt be hitting limp because requested boost would still be low, and yes I did run stock software when I first changed too k04 with no issues
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rob.mwpropane
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« Reply #124 on: May 12, 2012, 04:32:50 AM »

artite: when you first swapped the turbo and installed the k04, your car runs fine with k03 software?

Just picked up my car today and it's seems a bit weird. After 3000+ rpm the car seems to lose boost... acting like if I released the accelerator and I can hear the blowoff valve sending boost to intake again... but I'm WOT, which seems a lot weird. I read something about this can be "limp mode" because k04 is overboosting. Smiley

This can be fixed with ECU mapping or I'll need to trick my MAP with some kind of diode? Anybody have a clue on this?

You need to log to find out what's going on. It would be a good idea to find the root of the problem before changing anything, don't add a diode. That would just be putting a band aid on it, if it did in fact fix anything.

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azaiats
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« Reply #125 on: May 12, 2012, 09:13:36 AM »

Hi guys, thanks for replying me.

Today I get the car and a vag cable in hands... nicely dumped my flash to start analyzing it. First of all, let me explain: my car is a 1.8T GTI 2003. It was broken and forgoten in my house for almost 5 years... the turbine has blowed up. (Yeah, I'm kind of weird guy having a gti stopped for 5 years... hehe). Just leaved the gti and bought a bmw Smiley

The story: The turbine that blowed up was a k03s modified. My software is remapped too and the guy told me I'm making like 260hp with everything else stock (only K&N filter on original car box). The software was remaped by a well known brazilian chip tunning company who work only with german cars. They say that their chip is "powerfull but with safety". So I guess is very conservative.

Another thing to known: here our gasoline have at least 15% of sugar cane alcohool. Even the best gasoline (podium from Petrobras who says that the RON is 101 have 15% of alcohol). So, our octanes here is a little higher.

The car is really fast, but not so fast. It's faster than a k03s stock remaped for sure. I beated a lot of cars with it. Now, the car has a modified k04 (e05) and everything else stock (even the cat). I'm planning to remap it by myself as high I can and then buy some parts, like new injectors, maf, etc. Resume: it's a toy/hobby. I'm a computer scientist, so asm programming are simple to me, and these stuff are of my interest.

The car came back from the workshop and today I found a new situation: broken alternator... hehe... I bought a new battery to get my car back to the greasemonkey's... Smiley Found no other DTC's, just low voltage only, and ABS get weird when the battery died. Maybe this is the problem... the car isn't getting enough power to supply enough fuel pumping or other things... will fix this in the next week.

I'll upload my binary here to everyone who wants to explore it. Please make comments if you do so.

For now I'm looking LDRXN and I see:

90,0019   108,0023   111,5180   117,0025   154,5033   192,0041   192,0041   192,0041   192,0041   184,0821   176,1834   167,8395   158,6284   148,3391   138,1670   128,0184

These values are for sure really low compared to what artite are doing with their k04. Will start looking another things today, and I'll paste the results here for whom interested.

If anyone have any comments, please feel free to share Smiley
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2003 1.8T AUQ @ 06A906032HP - k04/e05 20psi - 317cc @ 4.5fpr - K&N @ stock box - ceramic clutch - 18" tsw wheels @ yoko's 235/45/18 @ eibach lowered springs

deka's 870cc in on the way down... boost wait for me Wink
azaiats
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« Reply #126 on: May 12, 2012, 02:27:31 PM »

After some hours of examination, here's the things I spoted:

Km/h limit
- VMAXNB increased to 300km/h; (+50)

RPM limit (I'll raise it up to 7000 in my tests, someone can tell me how safe is it?)
- NMAX increased to 6900; (+100)
- NMAXDVG increased all table to 6900 (+300)
- NMAXGA increased all table to 6900 (+100)
- NMAXDV increased to 6900 (+300)
- NMAXOG increased to 6900 (+100)

boost and their limits
- LDRXN map table is the same that a original 180PS until 1720RPM, then it's increased, but seems to be a lot different/conservative than suggested here by artite/
fredrik_a; max value = 192, which I can guess 1.2bar
- LDRXN and LDRXNZK are using the same values; (ignoring knock issues?!? or dealing with it on another maps)
- KFMIRL are identical maps from 180PS original (untouched); which I can guess is limiting boost to 1.2bar
- KFLDHBN is entirely FF'd; (unfinished work I guess... the tuning guy wont did their job well)

As far I can see, and understand (and I'm a completely newbie here), my car was never "tuned", just raised some boost and limit's and that's it...
Paid a real good amount of cash, and now I'm seeing these guys with different eyes... sadly.
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2003 1.8T AUQ @ 06A906032HP - k04/e05 20psi - 317cc @ 4.5fpr - K&N @ stock box - ceramic clutch - 18" tsw wheels @ yoko's 235/45/18 @ eibach lowered springs

deka's 870cc in on the way down... boost wait for me Wink
nyet
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« Reply #127 on: May 12, 2012, 02:43:13 PM »

Paid a real good amount of cash, and now I'm seeing these guys with different eyes... sadly.

This is why so many "non-pros" are doing their own tuning.
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« Reply #128 on: May 14, 2012, 04:57:35 AM »

This is why so many "non-pros" are doing their own tuning.

I was told go to pro tuner over and over so i did posted the map on here and told it was total shit lol
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azaiats
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« Reply #129 on: May 16, 2012, 08:25:11 AM »

Just to everybody knows: got my car back. Sucessfully loaded original k03 1.8T 180PS file on ECU. Came from a ride right now and guess what: the boost still cuting at 3000rpm.
 
Will spend my next hours trying to figure it out. I have no idea how to log things yet... if someone can point me, I'll be thankfull.
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2003 1.8T AUQ @ 06A906032HP - k04/e05 20psi - 317cc @ 4.5fpr - K&N @ stock box - ceramic clutch - 18" tsw wheels @ yoko's 235/45/18 @ eibach lowered springs

deka's 870cc in on the way down... boost wait for me Wink
azaiats
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« Reply #130 on: May 16, 2012, 09:49:29 AM »

Nevermind, just figured out how to log on vag-com. Did a log like artite one, here the results. Can someone please give me some advice that what is going on?

Group A:   '002            Group B:   '031            Group C:   '115         
   Idle speed   Engine load   Inj. period   Air mass in      Lambda Factor   Lambda Factor   Bin. Bits   Bin. Bits      Engine Speed   Engine Load   Spec. Boost   Actual Boost
TIME   700-820 rpm   15-25%   2.0 - 4.0 ms   2.0-4.5 g/s   TIME               TIME   700-6800 RPM   15-150%   990-1800 mbar   <=1800 mbar
STAMP    /min   %    ms    g/s   STAMP               STAMP    /min   %    mbar    mbar


365.07   680   21.1   2.72   3.42   365.39   1.016   1.000                         364.78   720   19.5   920.0   940.0
365.99   1440   44.4   5.44   12.53   366.29   1.000   1.000                         365.68   720   21.8   920.0   940.0
366.90   1480   72.9   8.84   21.89   367.20   0.969   1.000                         366.59   1360   70.7   1370.0   950.0
367.80   1720   83.5   9.52   29.22   368.10   0.945   0.953                         367.50   1600   78.2   1480.0   1020.0
368.71   2040   98.5   11.56   40.58   369.01   0.938   0.945                         368.40   1920   91.7   1690.0   1120.0
369.61   2400   119.5   13.26   57.33   369.91   0.938   0.945                         369.31   2280   112.0   1700.0   1290.0
370.52   2840   143.6   16.32   82.06   370.82   0.899   0.789                         370.21   2680   133.1   1690.0   1560.0
371.42   3400   162.4   26.52   100.61   371.72   0.750   0.891                         371.12   3200   168.4   1650.0   1990.0
372.33   3880   151.9   24.48   123.03   372.63   0.789   0.766                         372.03   3720   125.6   1620.0   1470.0
373.23   4400   119.5   17.68   111.83   373.54   0.789   0.727                         372.94   4240   118.0   1650.0   1630.0
374.14   4880   115.8   22.10   90.56   374.44   0.750   0.836                         373.84   4760   160.9   1660.0   2300.0
375.04   5360   162.4   34.00   169.56   375.35   1.000   0.883                         374.74   5200   148.1   1680.0   1900.0
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2003 1.8T AUQ @ 06A906032HP - k04/e05 20psi - 317cc @ 4.5fpr - K&N @ stock box - ceramic clutch - 18" tsw wheels @ yoko's 235/45/18 @ eibach lowered springs

deka's 870cc in on the way down... boost wait for me Wink
airtite
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« Reply #131 on: May 16, 2012, 11:00:06 AM »

best is to do a 3rd gear run starting at 2000 rpm till redline BUT from your log above at 3200rpm your boost spikes too 1900 where as requested boost is 1600 this is more than 300mbar and would cause limp, either your wastegate is not adjusted correctly or your n75 has a vacuum leak or isnt working properly
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azaiats
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« Reply #132 on: May 16, 2012, 11:13:06 AM »

My wastegate isn't touched by nobody. Just bought the k04 and the shop installed it as it is. Do you have any clue how can I adjust it?

My N75 is stock, and last week I just disconnected it and it retains some boost ( I guess 4psi ) without the car going to limp mode. Any other way to verify if N75 is working good?

Thanks again for the response, and sorry for asking a lot of newbie questions.
 
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2003 1.8T AUQ @ 06A906032HP - k04/e05 20psi - 317cc @ 4.5fpr - K&N @ stock box - ceramic clutch - 18" tsw wheels @ yoko's 235/45/18 @ eibach lowered springs

deka's 870cc in on the way down... boost wait for me Wink
azaiats
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« Reply #133 on: May 16, 2012, 05:50:46 PM »

Update: I guess I'll need to remap N75 to work with my actuator. I will deal with this later.

Just mapped to request 29psi at all just to test, and voilá. 22psi starting at 3,4k rpm, max of 24psi at 3,8k rpm. Never had a chance to pass 4k rpm in 3th (too fast/powerfull for a ordinary day/road drive) Smiley I read a little over the inet and saw that e05 turbo's are capable of 28/29psi, but it blows fast. I guess the manufacturer of this one that I bought have configured the wastegate for 24psi which people says that is the max for reability. So, the wastegate is good, the question is about N75 mapings to do the right job.

Cold hard facts: my K04 isn't a K03/hybrid, it's a K04-001 with E05 spool (probably a k04-020 internals). The turbocharger is way bigger than k03s and you only start to feel it at 3k rpm.

MAF limit DTC showed up. Will limit it higher and see what happens. Now it's time to improve my logs and log N75.

Another strange thing is that my car is a VW golf, but the ECU/software is for an Audi 1.8T ECU. Sincerely I'm no sure if my car is running 3bar or 4bar FPR. Need to verify this thing too.

But for sure, an upgrade to e05 definitely can't run with stock software. Limp mode will happen at 2500rpm and the car feels like shit.
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2003 1.8T AUQ @ 06A906032HP - k04/e05 20psi - 317cc @ 4.5fpr - K&N @ stock box - ceramic clutch - 18" tsw wheels @ yoko's 235/45/18 @ eibach lowered springs

deka's 870cc in on the way down... boost wait for me Wink
airtite
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« Reply #134 on: May 16, 2012, 11:32:19 PM »

the n75 should still control the boost and hold the wastegate open even with your e05 on stock software, I have had a few guys with turbos where the wastegate has been either tightened right up so it cant open or the wastegate was actually stuck....... my suggestion would be too load your stock map first and log things like n75 duty cycle, boost, throttle position
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