What happens after stage 2+

Hurdy

Yorkshire - born and bred
Oct 7, 2008
709
7
South Yorkshire
Welcome Danneth. Good to see you on here[B)]

If you look at my signature then you'll see where I am on a slightly uphill "private drive";) on normal road tyres.

To the OP - There's plenty of extra room for improvement over what you have already mentioned.

- The Forge actuator has turned out to be a great little mod once set-up, but you really need VCDS and REVO with the SPS+ controller to get the most out of it.
- A little known mod, but cheap and effective is the RS4 fuel return valve for the high pressure fuel rail. Should enable you to reach requested fuel pressure (and a bit more!!;) )
- Performance cams - quite expensive for what they are. You could just go for the intake cam as that is where the power gains are - bang per £ isn't good though.
- Port and polish - £350 will get you a port and polish for the head and manifold to free up a few horsies.
- Hybrid K04 - The guys in the USA are talking about this at the moment, basically a stock K04 with refurbed turbo impellers, uprated bearings and a port out for the housing to help the turbo spool quicker and push more air.

realistically though, if you are going to do all the above you would be lucky to push 390bhp, which is Garrett GT2871R territory and would most likely cost the same, but you would lose low end spool and urgency with the GT2871R wheras the Hybrid K04 etc would see mad spool and a very aggressive midrange punch of well over 400 wheel lbft

Now to my favourite bit, the DSG.......

In my opinion it is the sole reason for buying an ED30 over a Cupra and with REVO stage 2 mapping does exactly what it should have done from the factory.

Ups the torque handling limit to 600nm - 440lbft.
I'm running over 400lbft and don't have a smidge of clutchpack slippage.
Gearchanges in less than two hundredths of a second, with virtually no loss in power delivery.
Manual mode is exactly that and also enables you to utilise the fullfat 7400rpm limit.
Sport mode is manically fast. I've NEVER been in the wrong gear with the REVO stage 2 in sport mode and again it uses the full rev range.

At the 'ring last year the DSG was truly awe inspiring and this year I'm back to do a trackday (no bikes, vans, coaches etc) alongside Porsches, Ferrari's Lamborghini's etc, to see exactly what the car can do with a full track set-up including the Quaife diff, engine mounts etc....

I guess what I'm trying to say is that it isn't all about ultimate power and how fast the car can go in a straight line, but more how the car handles and performs on track or fast road use that inpires how anyone should feel about their car. A car with a supercharger strapped to it that can do 12.?? seconds down the Pod is impressive, but without supporting brakes, suspension etc it will only be a one dimensional car and not the full fat package - and to get that simply costs money, no matter what car you buy:)
 

Poverty

Guest
Hurdy,

Tell us more about the rs4 fuel return. Im wondering if it has the potential to cure the flat spot people have been suffering from.
 

Hurdy

Yorkshire - born and bred
Oct 7, 2008
709
7
South Yorkshire
Hurdy,

Tell us more about the rs4 fuel return. Im wondering if it has the potential to cure the flat spot people have been suffering from.

The RS4 fuel return valve replaces the OEM one. The OEM one opens a return valve at 130bar and allows pressure to drop to as low as 127bar before building pressure back up again. On the RS4 valve the pressure is designed to go to 136 bar and then the return valve opens, but closes again at 130bar. All depending on requested rail pressure.

REVO Stage 2+ requests 130bar and then higher in the rev range 132.5bar around the mythical 5krpm mark.

Before I had the valve, my actual rail pressure never managed to meet requested pressure apart from the point where I let off WOT. This POSSIBLY could point to a performance dip if the ECU detects the inability to meet requested pressure and then back off the power.

There is no definitive proof on this, but since I had the RS4 valve fitted the dip in power has disappeared, although this could also point towards the Forge actuator as this was set-up at the same time as the valve was fitted.

There is also a by-product of fitting the RS4 valve and this is that it alters the pressure in the in-tank low pressure pump. The OEM low pressure fuel pump before the valve was fitted started off at 4.5bar pressure, but gradually dropped to around 3.4bar pressure at higher revs when WOT. After the RS4 valve was fitted the in-tank pressure stabilised at between 4.1-3.9 bar across the entire run whilst WOT. This too could point to where you would get a drop in power around 5krpm as the in-tank low pressure fuel pump drops below 3.5bar around those revs, which is outside normal parameters and MAY cause fuel cuts or the ECU to back off the power.

The RS4 valve can cope with up to 150bar of pressure requests (GIAC Extreme Beta file testing), which is the limit of the high pressure fuel pumps anyway.

I must stress that all this is from readings taken from live logging on my car, but the diagnosis is subjective although compelling in the logic.

The valve costs under £50, but is a pig to fit as it is located under the intake manifold and at an awkward angle to reach with spanners. I for one think it was worth it, just for peace of mind that it eliminated another variable from the "power dip syndrome"

:)
 

Poverty

Guest
The RS4 fuel return valve replaces the OEM one. The OEM one opens a return valve at 130bar and allows pressure to drop to as low as 127bar before building pressure back up again. On the RS4 valve the pressure is designed to go to 136 bar and then the return valve opens, but closes again at 130bar. All depending on requested rail pressure.

REVO Stage 2+ requests 130bar and then higher in the rev range 132.5bar around the mythical 5krpm mark.

Before I had the valve, my actual rail pressure never managed to meet requested pressure apart from the point where I let off WOT. This POSSIBLY could point to a performance dip if the ECU detects the inability to meet requested pressure and then back off the power.

There is no definitive proof on this, but since I had the RS4 valve fitted the dip in power has disappeared, although this could also point towards the Forge actuator as this was set-up at the same time as the valve was fitted.

There is also a by-product of fitting the RS4 valve and this is that it alters the pressure in the in-tank low pressure pump. The OEM low pressure fuel pump before the valve was fitted started off at 4.5bar pressure, but gradually dropped to around 3.4bar pressure at higher revs when WOT. After the RS4 valve was fitted the in-tank pressure stabilised at between 4.1-3.9 bar across the entire run whilst WOT. This too could point to where you would get a drop in power around 5krpm as the in-tank low pressure fuel pump drops below 3.5bar around those revs, which is outside normal parameters and MAY cause fuel cuts or the ECU to back off the power.

The RS4 valve can cope with up to 150bar of pressure requests (GIAC Extreme Beta file testing), which is the limit of the high pressure fuel pumps anyway.

I must stress that all this is from readings taken from live logging on my car, but the diagnosis is subjective although compelling in the logic.

The valve costs under £50, but is a pig to fit as it is located under the intake manifold and at an awkward angle to reach with spanners. I for one think it was worth it, just for peace of mind that it eliminated another variable from the "power dip syndrome"

:)


any chance of a part number. Will get my mate to fit this onto mine.

Cheers
 

Al

Active Member
Aug 29, 2005
7,326
9
Thats whats getting done on mine next week. I did ask if it was worth fitting an uprated actuator also, but I am not sure that it is based on what I have read/heard. John - did you uprate your OEM in tank pump yet?
 

owen lcr

orvil
Oct 10, 2006
1,179
0
montrose, scotland
yeah i am getting this part fitted in 3 weeks when i get the extreme map. hoping it makes a differance, i havent got a flatspot but it will mean the pump i have on now isnt working to nearly it 100% capacity/ability. do you know if anyone is running the extreme file yet hurdy and what numbers/gains they are claiming? i was going to go for the uprated actuator but it isnt an easy install to tie in with the GIAC software as it isnt tunable to the average user. unless GIAC bring out a new map that is set up to run with a non OEM actuator it is a no go for me, i doubt that GIAC will do this anyway!
 

Hurdy

Yorkshire - born and bred
Oct 7, 2008
709
7
South Yorkshire
Thats whats getting done on mine next week. I did ask if it was worth fitting an uprated actuator also, but I am not sure that it is based on what I have read/heard. John - did you uprate your OEM in tank pump yet?

No need to uprate the in-tank pump unless you consistently drop below 3.5bar and even then you can get away with it if you aren't WOT all the time. With the RS4 valve you shouldn't see less than 3.8bar at the least.
 

Hurdy

Yorkshire - born and bred
Oct 7, 2008
709
7
South Yorkshire
yeah i am getting this part fitted in 3 weeks when i get the extreme map. hoping it makes a differance, i havent got a flatspot but it will mean the pump i have on now isnt working to nearly it 100% capacity/ability. do you know if anyone is running the extreme file yet hurdy and what numbers/gains they are claiming? i was going to go for the uprated actuator but it isnt an easy install to tie in with the GIAC software as it isnt tunable to the average user. unless GIAC bring out a new map that is set up to run with a non OEM actuator it is a no go for me, i doubt that GIAC will do this anyway!

There are a couple of cars running Beta GIAC Extreme files here in the UK and also one in Greece that has full bolt-ons and ran 393bhp:whistle:
 
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