max boost exceeded after fitting R Intercoolers to LC

[Phillc]

I have just put the twin intercoolers from a cupra r on my cupra (leon) it is running ok but has thrown up some fault codes the main one is the boost, before it was running to 10psi now it goes to 18ish but wont hold it and drops to 8/9psi the fault code Say's that the max boost has been exceeded, which i knew due to the boost gauge, can i adjust the max boost via vag com or will it only be sorted with a remap, there was a fault code that said something about the pressure in the inlet manifold was high i think this is connected to the boost, but prob wrong any advice would be very welcome.

 

[andycupra]

i presume this car is not remapped?

if so then just changing over to 2 intercoolers should not lead to 18psi of pressure.

How have to completed this mod? have you changed the inlet manifold? are the intercoolers mounted as on the R.
have you changed any other piping?

 

[Phillc]

No not remapped....it has resulted in the boost change though, everything changed all intercooling piping, cupra r inletmanifold,and boost pipe.
here is a pic..
http://farm4.static.flickr.com/3020/2593084866_70d6615faf_b.jpg

 

[Willie]

Have you tried ECU reset since fitting all this kit?
Have you tried double checking all sensor wires etc?
Find it difficult to believe that you would have more boost with doing this, not that I'm saying your lying but as with you its just difficult to believe. Too low boost I would have believed more but more boost???
What did you do with map sensor, are they different between the two set ups?

 

[Phillc]

I used the map sensor that came with the pipe work, i disconnected the battery and left it for over an hour before starting the car, not to sure how to do reset thought leaving for 30mins was the way to go, its not just the boost gauge that says the boost increase its vag com as well, i will try to run some logs and post them so you can look at the read outs.

 

[Willie]

Yup that process will reset the ECU.
Will be interesting when logging the boost we'll see why and where is comes up and spikes and what happens after the spike

 

[Phillc]

not done logs before can you give me any pointers and what things to log.
apart from the boost, oh and where do i find the boost.

 

[Willie]

Try a search on the vag com section on this forum.
It'll tell you the blocks to log.
I'm no expert but suppose you want to know how much air is getting into the induction (MAF), how much boost (boost) also log compared to RPM's. This will show as RPM's rise how the MAF reading and boost are effected. This might show some sort of fault. Might!!

 

[Phillc]

cheers willie, i have just done that found info so i am out to do them now.

 

[Willie]

http://www.seatcupra.net/forums/showthread.php?t=160741&highlight=boost+rpm+maf

One of your posts Phil, lol

Short memory??

 

[DPJ]

High boost level on an unmapped car would suggest a blockage to me.

 

[andycupra]

interesting, there is now more pipework to fill with boost, so like said above id expect lower boost.

I would wonder if using cupra R pipework and sensors, eg map sensor means that different information or signals are being sent to the ecu, or they are interpreted differently as the ecu is different for the parts used.
Can you use the original map sensor?
If i was doing this mod id want to retain as many of the orignal sensors as possible.
Some of the pipes may now head off in different directions than before, check you have everything plumbed in the right way.

 

[DPJ]

He said he saw the high boost on the gauge too............

 

[wild willy]

Have you been fiddling with the turbo wastegate maybe.

 

[Phillc]

not touched anything except pipe work, just replaced all the LC stuff with R, i have done my logs now how do i get them on here please. the sensors are the same , part numbers are anyway.
Cheers.

 

[Phillc]

Hope someone can make head or tale of this its way above my head

 

[Phillc]

these are my logs.

Group A: '003
Idle speed Air mass in Throt Angle Ignit Angle
TIME 700-820 rpm 2.0-4.5 g/s 0.2-4.0% 0-12 BTDC
MARKER STAMP /min g/s % °BTDC
0.53 2520 68.25 100 18
1.33 2680 90 100 9.8
2.15 2880 118.56 36.1 4.5
3.04 3080 80.47 22 14.3
3.86 3240 86.78 23.1 12
4.76 3400 95.42 23.1 15
5.57 3560 98.78 23.1 12
6.47 3760 103.75 23.5 12.8
7.27 3920 109.31 23.9 11.3
8.18 4120 115.61 24.7 15
8.99 4280 120.28 25.5 12
9.79 4440 125.19 26.3 11.3
10.69 4600 130.97 27.5 15
11.49 4760 133.92 28.2 13.5
12.42 4920 139.03 29.8 11.3
13.31 5080 144.06 30.6 12.8
14.32 5240 147.06 31.4 12
15.12 5360 149.69 32.2 15
15.94 5480 153.17 32.9 12.8
16.83 5640 153.39 32.9 15.8
17.65 5760 156.14 32.9 15.8
18.45 5840 156.89 32.9 15



Group B: '020
Idle Stabilization Idle Stabilization Idle Stabilization Idle Stabilization
TIME
STAMP CF CF CF CF
0.93 0 3 3 0
1.75 0 3 3 0
2.55 0 3 3 0
3.44 0 3 3 0
4.36 3 2.3 2.3 0
5.15 3 2.3 2.3 0
6.07 2.3 2.3 2.3 3
6.87 2.3 1.5 1.5 3
7.68 2.3 4.5 1.5 3
8.59 1.5 4.5 1.5 2.3
9.38 1.5 4.5 3.8 2.3
10.29 0.8 3.8 3.8 1.5
11.1 0.8 3.8 3 1.5
11.9 0.8 3.8 3 1.5
12.91 0 3 3 0.8
13.82 0 3 2.3 0.8
14.72 0 3 2.3 0.8
15.52 0 2.3 2.3 0
16.43 0 2.3 1.5 0
17.25 0 2.3 1.5 0
18.05 0 1.5 1.5 0
18.85 0 1.5 0.8 0

Group A: '115
Engine Speed Engine Load Spec. Boost Actual Boost
TIME 700-6800 RPM 15-150% 990-1800 mbar <=1800 mbar
STAMP /min % mbar mbar
0.77 2160 112.8 1670 1500
1.67 2280 124.8 1620 1660
2.48 2440 140.6 1620 1860
3.38 2600 150.4 1630 2180
4.18 2720 118.8 1630 1890
5.09 2840 120.3 1630 1840
5.89 2960 122.6 1630 1930
6.71 3080 122.6 1630 1970
7.51 3200 122.6 1610 2010
8.32 3320 124.1 1610 2060
9.31 3440 124.1 1590 2090
10.23 3560 124.8 1600 2140
11.12 3720 124.8 1600 2190
11.94 3840 124.8 1630 2230
12.74 3920 125.6 1630 2290
13.54 4040 125.6 1640 2300
14.35 4160 126.3 1640 2310
15.15 4280 127.1 1640 2310
15.95 4400 127.8 1640 2300
16.86 4520 128.6 1640 2290
17.66 4640 129.3 1640 2260
18.57 4760 130.1 1640 2250
19.39 4880 131.6 1640 2230
20.27 5000 128.6 1590 2210
21.18 5120 127.1 1580 2210
22 5200 127.1 1570 2220

Group B: '020
Idle Stabilization Idle Stabilization Idle Stabilization Idle Stabilization
TIME
STAMP CF CF CF CF
0.36 3 6 3 3
1.27 2.3 6 6 6
2.07 2.3 6 6 6
2.98 2.3 6 6 6
3.78 2.3 6 6 6
4.59 2.3 5.3 6 6
5.49 2.3 5.3 5.3 5.3
6.29 1.5 4.5 5.3 5.3
7.11 1.5 4.5 5.3 5.3
7.91 4.5 4.5 4.5 5.3
8.82 4.5 4.5 4.5 4.5
9.71 4.5 4.5 4.5 4.5
10.72 3.8 3.8 3.8 3.8
11.52 3.8 3.8 3.8 3.8
12.34 3.8 3.8 3.8 6.8
13.14 3 3.8 3.8 6.8
13.94 3 6.8 3 6
14.75 6 9.8 6 6
15.55 6 9.8 6 6
16.35 6 9.8 6 5.3
17.26 5.3 9 5.3 5.3
18.08 5.3 9 5.3 5.3
18.98 5.3 9 4.5 4.5
19.87 4.5 8.3 4.5 4.5
20.69 4.5 8.3 4.5 4.5
21.6 4.5 8.3 4.5 4.5

Group A: '031
Lambda Factor Lambda Factor
TIME
STAMP
0.41 0.969 1
1.31 0.984 1
2.22 0.953 0.945
3.12 0.922 0.938
3.93 0.922 0.945
4.83 0.945 0.945
5.65 0.938 0.945
6.54 0.945 0.945
7.34 0.938 0.945
8.16 0.938 0.945
9.05 0.922 0.93
9.87 0.93 0.922
10.67 0.914 0.914
11.47 0.906 0.906
12.28 0.883 0.891
13.18 0.867 0.875
13.98 0.86 0.86
14.79 0.86 0.852
15.69 0.828 0.875
16.51 0.938 0.953
17.32 0.938 0.953
18.22 0.953 0.961
19.13 0.992 1
20.02 0.984 1
20.82 0.992 1
21.74 0.86 0.875
22.55 0.828 0.836
23.45 0.774 0.797
24.25 0.75 0.789
25.06 0.75 0.789

Group B: '032
Idle O2 Adapt Run O2 Adapt
TIME -10.1 -10.1
STAMP % %
0 2.4 -0.8
0.91 2.4 -0.8
1.82 2.4 -0.8
2.62 2.4 -0.8
3.53 2.4 -0.8
4.43 2.4 -0.8
5.23 2.4 -0.8
6.05 2.4 -0.8
6.94 2.4 -0.8
7.76 2.4 -0.8
8.56 2.4 -0.8
9.45 2.4 -0.8
10.27 2.4 -0.8
11.07 2.4 -0.8
11.87 2.4 -0.8
12.78 2.4 -0.8
13.58 2.4 -0.8
14.39 2.4 -0.8
15.21 2.4 -0.8
16.09 2.4 -0.8
16.91 2.4 -0.8
17.8 2.4 -0.8
18.62 2.4 -0.8
19.62 2.4 -0.8
20.42 2.4 -0.8
21.24 2.4 -0.8
22.14 2.4 -0.8
23.05 2.4 -0.8
23.85 2.4 -0.8
24.65 2.4 -0.8

Group B: '118
Engine Speed Air Temp In Boost Dut Cyc Actual Boost
TIME 700-6800 RPM <=110 C 0-100% <=1800 mbar
STAMP /min °C % mbar
0 2280 21 0 1010
0.36 2280 21 0 1010
0.76 2240 21 5.1 980
1.18 2280 21 5.1 1100
1.67 2360 20 5.1 1370
2.07 2440 20 5.1 1550
2.47 2520 18 5.1 1720
2.87 2600 18 5.1 1910
3.29 2680 18 5.1 2210
3.69 2800 18 5.1 2170
4.09 2840 17 5.1 1970
4.49 2920 17 5.1 1890
4.89 3000 17 5.1 1900
5.29 3080 17 5.1 1940
5.69 3160 17 5.1 1980
6.11 3240 17 5.1 2020
6.6 3320 17 5.1 2060
7 3400 17 5.1 2080
7.4 3480 18 5.1 2110
7.82 3560 18 5.1 2150
8.31 3640 18 5.1 2180
8.81 3760 18 5.1 2220
9.22 3840 18 5.1 2250
9.72 3920 18 5.1 2310
10.12 4000 18 5.1 2330
10.63 4080 18 5.1 2340
11.03 4200 18 5.1 2350
11.45 4240 18 5.1 2340
11.93 4360 19 5.1 2340
12.33 4440 19 5.1 2320
12.74 4520 20 5.1 2310
13.14 4600 20 5.1 2300
13.54 4640 20 5.1 2290
13.94 4720 21 5.1 2280
14.36 4800 21 5.1 2270
14.74 4840 21 5.1 2250
15.16 4920 21 5.1 2250
15.67 5000 21 5.1 2230
16.07 5080 21 5.1 2210
16.57 5160 22 5.1 2210
16.97 5240 22 5.1 2200
17.37 5280 23 5.1 2190
17.78 5320 23 5.1 2180
18.28 5400 23 5.1 2170
18.68 5480 24 5.1 2160
19.08 5520 24 5.1 2150
19.49 5560 24 5.1 2160
19.99 5640 24 5.1 2140
20.39 5680 24 5.1 2130

 

[DPJ]

Certainly is overboosting, isn't it. Also running very lean. Take care.

I doubt it's a blockage, seeing the logs.

 

[DPJ]

N75 is trying it's hardest to open the wastegate.

Is the line N75 - actuator etc connected up, not split?

 

[Willie]

Your getting mega boost there dude
As DPJ says looks like its asking for the correct boost but getting what you'd expect from a remapped car, 19 PSI is good going even for a remapped car.
Doesn't even spike then drop off, very strange
Does your DV work okay?
Can you still here it dump?