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Author Topic: Hello From Birmingham UK (My disaster story  (Read 3959 times)
markpowell35
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« on: September 13, 2015, 05:04:36 AM »

I thought i'd introduce myself and give a breif story as to how i came across this forum.

I currently own an Audi S3 8l 2002 BAM which had a revo stage 1 remap and car was standard, i brought it with the cambelt snapped and head shot back in september 2014. I did this because my Leon Cupra R 2003 BAM was written off the month before leaving me a full donor car for the Audi as there identical under the shell aside from the 4wd.

6 weeks ago  i was near completion of fixing an exhaust manifold leak before going to get my Car live mapped for pretty much a stage 3 setup (BBT hybrid turbo, 550cc, 3" TIP & DP, Pro 4 Mani and DM Forged Rods) when disaster struck 2 days before i was booked in, after waiting 3 months Sad

The guy helping me rebuild and Port the top end was having issue's reading an astra ecu he was also working on so he read my cars ECU to test his cable etc was working. The day before he read my car's ECU it was built, running and nearly ready to go just had a slight boost issue as was only running wastegate 14psi pressure, suspected n75 but anyway so i get there and go for a drive after changing n75 and it runs like shit no boost, would not rev past 5500 rpm and checking throttle position with vcds would only open to 30% and fuel was at 0.75 constantly under load. Swapped the n75 back and still exactly the same. so now with one day to go before i was booked in for mapping i had a major issue one could about o2 sensor was thrown so i ordered one for next day, cleared the code and it didn't come back anyway but made no difference something was majorly wrong. I tried to use my ECU from the leon but it was immobilized so engine would start and cut out, not knowing anything about ECU's at this point i found a website with orignal audi ECU dumps and asked the guy who read it to write this file
 (http://www.chip-tuner.hu/original_ecu_files/files/Audi/Audi%20S3%201.8T%20225HP%208N0906018BH%200261207751%20362999.zip)
to my Seat Leon ECU this wrote successfully but car still would run. 

I then stumbled accross this link.

http://www.vask.org.nz/index.php?topic=19147.30

exact same issues, so either it was Revo tamper protection and so stuck in Revo's Valet Mode or was a Bad read of the ECU.

So i took the car up for tuning explained the situation and that i just replaced the O2 and now the O2 reading was backwards but car still ran the same, i explained i had the orignal O2 sensor and a spare ECU from my Leon Cupra R that needs the immobilizer removing.

I got a call two days later to see i might aswell come and pick the car up because the O2 sensor was shot and i needed a bigger intercooler and the i'd have to wait another 8/9 weeks to get booked back in. They did however unlock my leon ECU and when i got home i plugged it in and changed the O2 sensor again and now i had a car that would rev normally, and deliver fuel as it should however... i now had a stage 3 ready car on a standard map so it was asking for 0.9bar boost and it was building boost so quick it would over shoot and cut off by 3500 rpm Sad

So this got me thinking as i'm Computer engineer by trade and have a mechanical background as a hobby for the last 15 years i thought i'd give this whole re-mapping thing a go.

I've spent the last 4 weeks gathering everything i need to see my ECU dumps and located maps etc and i have spend endless nights trying to get a general understanding of each one affects each other.

As i had a half working read that caused this ecu issue in the first place and the original 08N0906018BH file i flashed my spare ecu with i've been looking over the differences between the maps and cross referencing all of that with stuff off the s4wiki and alot of info off here, i have had lots attempts and trial runs i'm finally getting somewhere.

I think now i need a little guidance from the pros on two things if anyone would be so kind Smiley my original audi ECU is still in the same state some sort of locked valet mode i'd like to find out if this is recoverable as attempts to write to it using OBD always fail only the original read can be written to it through OBD.

and Secondly if someone can help me tune the boost/n75 maps to control turbo pressue properly as it overshoots all over the place at the moment.

 Smiley
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adam-
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« Reply #1 on: September 14, 2015, 12:10:26 AM »

That's a well documented story - was a good read first thing this morning! Smiley

Sounds like you're already doing pretty well tbf - the Wiki is a fantastic source of information to help you get started.  If you can, get your fuelling tables prepared.  Generally, a it's a pretty standard method - the numbers are usually the same to get into a safe zone.  They can be tweaked later - but get fuelling down around 0.8 at peak torque (where you think that would be), and enriching to 0.76 at the limiter for just now.

Get ME7Logger working so that you can log fuel - sometimes you need to pull the cluster fuse to get it to connect, but it's so much better than VCDS it's unreal.  Get it done!

You'll need to get a KRKTE and TVUB values for the 550cc injectors.  They're the Bosch ones, right?  They're pretty well documented and it won't take too long to find them.  There's standard values for different injectors but they're pretty well documented online.

Once you can successfully log fuel, you're ready to start dialing in timing.  Are you wanting to map the whole thing yourself, or get a base map on it and then get it mapped?  Assuming Rtech (their waiting list is always massive!)?

Use your spare ECU and forget that Revo crap! You can flash over the Revo stuff if you bootmode it.  Bootmoding isn't that hard - get yourself some cut ECU connectors from a scrappy and make up a little harness.  You basically connect to the ECU, ground out one pin and it goes into bootmode.  You can flash over anything and put it back to stock.

I'd be looking at having your spare ECU de-immo'd and with a safe stock flash, and running your original ECU (wiped) with YOUR map, not Revo's.  Carry the spare immo incase you brick your original ECU - which you won't, btw, unless you're being broken.

So, once you've got fuelling, logging and your ECU issue sorted, get the turbos dialled in.  It's just a case of logging some boost making variables and adjusting until it makes good boost. 

I know this is quite a lengthy reply - but there's a lot to talk about.  What MAF are you using btw?  Still the 3" MAF?

If you can bootmode the ECU - you can flash ANY file with the EEPROM to match.  It would mean you can run a more documented file.  Going on that too, what software are you using?  WinOLS allows you to compare maps - where the software just looks for similarities and matches them up.

If you can get a well documented file on the ECU - 032HN 0002, maybe 032HN 0001, there is near enough fully documented .kp files for them.

I guess that's a lot to take in - but read the Wiki time and time again, make notes, and get stuck in.
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markpowell35
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« Reply #2 on: November 18, 2015, 05:17:24 AM »

Hi Mate,

didn't realise you'd replied to this one but thanks for the advice, i did much follow what you said, Been using WinOLS to compare the revo file, whcih was a great learning curve to be honest. I now have a fully defined 8N0906018BH .kp file there wasn't one available when i started Smiley

Managed to flash over a Leon Cupra R ECU that i had immo'd off

I didn't realise the fuel has to go so rich up top? 0.76 i've only gone as low as .081 so far. & yes still using 3" MAF

Just to check is the best practice -> Fuel -> Timing -> Boost     or Boost before timing?

Again thanks for the info Adam

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adam-
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« Reply #3 on: November 18, 2015, 05:20:54 AM »

Good stuff man.  Depending how much effort/work/time you've put into it, you might wanna throw your new defined file and .kp onto the ECU Definitions section incase anyone else needs it.  Good karma and all that.

Sounds like you've progressed pretty well man! Well done.  You'd get away with 0.80 at the top end, I just like mine pretty rich as it's better to be safe that sorry.  I'd say fuel, boost, timing. 

Get your boost following a good profile and then get timing in.  Obviously if you've got boost at say, 16psi and you have knock, timing will come first.  Don't be smashing more boost in when you've already got CF, you'd need to massage timing at that point.

So probably, fuel, then massage boost and timing at the same time and monitor/log results.
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