Audi S3 GT3582R stroker Build (previously GT3071r)

[tufftybloke]

Spent an hour or so on the dyno this afternoon.... I put the boost control back in the hands of the N75 and Bill loaded up the T1 file (the first file used from the original mapping).... couple of loaded sweeps indicated the boost request was still a little high hitting 28psi so a quick adjustment and hit 23/24psi so used that as a start...

First run netted 325bhp with no timing pull and fuelling at 12.5 AFR, added a little timing and then got a shade under 350 bhp @ 7300rpm again with no timing pull but then things were starting to go wrong... again!!!...

There was a rather large cloud of 'smoke' coming from under the car... only seemed to kick in at high rpm's which was odd... I currently have the PCV exiting down behind the back of the gear box until I get around to fabricating a catch tank so the first though was that the engine was breathing heavy and my heart sank... pulled the PCV connection off the top by the rocker cover outlet to see what was coming out while Bill loaded up the engine... hummm... nothing unusual, the normal amount of smoke you'd expect and no oil but not the huge clouds we saw on the dyno runs... it was only when Bill did a full run that the cloud appeared again... it was coolant leaking out from a water pipe somewhere by the turbo!!! DOH!!!

Bugger.... no point in doing much more until I find the leak... only happens under full load and high RPM so will be fine to drive normally for now but from the logs etc it appears that this first map file is a better start point than the run I have been running up until now...

On the road liquid is showing 291g/s and she certainly pulls well but feels flatter/laggier on initial spool so indicates the timing needs attention... no fuel dumping either so far but until I get the coolant leak sorted further tweaks will have to wait...

Onwards and upwards...

<tuffty/>

 

[tufftybloke]

Had a chance to log the car last night.... added in a few more degrees timing and left boost at 22/23psi...

Think thats about as much timing as I would like to see but will see what Bill says... IAT's are pretty good... ambient at the time was 18 deg IIRC... long term fuel trim is pulling 8% fuel at the time so will check that on the dyno and get the map tweaked to include the extra timing and get some comparison graphs to see where we are...

<tuffty/>

 

[tufftybloke]

Did some more road logging this evening...

Pulled a single 6 right towards the end but to be fair it was seeing over 23 degrees of timing advance at a tad over 22psi with an empty tank of 2 week old v-power so not all bad...

N75 duty cycle is quite lethargic which accounts for the more 'progressive' feel of the power coming in and maybe timing advance could be moved up a bit to help spool....

This is still the first ever map I had after I finished fitting the GT30 on the first time, its not too far out tbh... I have played with Unisettings to add timing, reduce load (as the boost was far too high) and pull some fuel out as the long term trims where quite high..

Fuel trims still a little high so more fuel may need to be taken out...

IAT's were good, ambient was about 17deg at the time and got no more than 32 deg on the log with the IAT's recovering to low 20's... happy enough seeing as I was only doing short runs locally on short roads and just going 20mphish in between runs so not really getting much air through to help...

Only one fault code (16825 - EVAP Emission Control Sys: Incorrect Flow) and the same one I have been having since disconnecting the vacuum to the EVAP system so need to get that coded out...

Doubt I will get a new map before GTI but I may try increasing the load a bit to up the boost and see where I can get it too... 1.6bar would be a nice start point I think but will have to have a play and check the timing (might pull a deg or 2 out)

<tuffty/>

 

[8bit]

Looking good

Quick question - you mention N75 duty cycle, are you seeing it on that log?

 

[rsrich]

Tufty, what turbine and hot housing spec did you end up with?
cheers
Rich

 

[ibiza_95]

id love to understand what youve just said but i dont, however this impresses me a lot, id love to undertsand it all... one day

 

[tufftybloke]

Looking good

Quick question - you mention N75 duty cycle, are you seeing it on that log?

Yes... block 118, Load %

Tufty, what turbine and hot housing spec did you end up with?
cheers
Rich

The original turbo came with a 0.64a/r T25 housing and 56.5mm 84 trim turbine... when I had it rebuilt I kept to the same 0.64a/r T25 housing but had a GT30 cartridge with a full size 60mm 84 trim turbine

<tuffty/>

 

[wild willy]

Great work tuffty, its the final tweaking and adjustments that take all the time but yield the results. Boost vrs timing vrs fueling is a tricky art to get it spot on. Too much in one direction upsets the other....... very addictive though.

 

[tufftybloke]

I have been doing a lot of data logging over the past few weeks and I am just waiting on a map revision once everyone concerned has time to fit me in (I am in no real hurry and paying customers come first)

Anyhoo... I have been having a few issues with boost control. I am currently running just N75 having taking the MBC out of parallel and the car is driving very nicely but I am running the ECU on reduced load through Unisettings to curb the boost spikes and random boost control... would appear that as I increase load to get boost much above 1.6bar then it becomes a lottery as to what I get... Saturday afternoon while taking a mate out for a little run I was hitting 1.5/1.6bar on the outbound trip and 2bar on the inbound trip... the EGT's went higher than I would like and she felt less urgent than before... obviously the really high boost is the reason but some boost control would be nice...

Anyhoo, I have backed off the load again until the revised map is ready and I can get her on the dyno for a more controlled test...

I do have a feeling though that I am getting to the limit of usable/reliable boost at around 1.6bar with the combo of the small port inlet mani and a T25 flanged hotside... much beyond that boost then flow restrictions kick in and all I get is heat...

Most of this is speculative until I get the revised map and get her on the dyno so in the mean time I thought I would try something that will at least help and be one less thing hampering potential for performance...

...a SEM inlet manifold

Bill has one lying about the workshop in the usual 'if I leave this in plain sight of tuffty he cannot resist...' type fashion... ok, he doesn't really do that but its all the justification I normally need lol... so I took it home this evening and set about test fitting to see what work I will need to do to get it to fit how I want it...

The SEM and S3 inlet manifolds...

...the SEM has my R32 TB on it of course...

...bolted onto the engine...

...injectors and wiring loom sit higher and may need adjustment + wiring extending or re routing to allow me to fit the top cover. The FPR is sticking up the most as you can see here so tilts the cover up a bit... I reckon I can do something with it though...

...the trim at the front looks as though it will go on too but there is nowhere (currently) to bolt the EGT probe black box and the metal plates bolt holes don't line up with the SEM's mounts for it so I will need to do a little tweaking there too...

...the charge pipe also needs some work as the SEM moves the TB further forward and straighter than the OEM mani...

So, looking plausible and with a bit of work I reckon I can keep the top cover too...

<tuffty/>

 

[ibizacupra]

lol, you could'nt resist

 

[tufftybloke]

lol, you could'nt resist

No mate... being surrounded by shiny things at yours its inevitable... although I am doing quite well resisting the GT35 lol

<tuffty/>

 

[Gulfstream]

I notice you bolted on the TB with the flap valve hinge on the side... Mine came with instructions from INA to have the hinge on top.. any reason in particular you choose that orientation?

 

[tufftybloke]

I notice you bolted on the TB with the flap valve hinge on the side... Mine came with instructions from INA to have the hinge on top.. any reason in particular you choose that orientation?

No reason... its the same way round as the std TB on the OEM mani... it has to be said that the TB does push down on the coolant hosing going from the top of the rad to the side of the head so using the TB in the orientation INA suggests may prevent that but it was in there long enough for me to really pay too much attention...

<tuffty/>

 

[wild willy]

Have you considered an ebc tuffty. Its transformed the power delivery on mine. If your looking for a flatline boost curve you will get it. 4 hours to fit and a great boost gauge too with an aux output to bring on wmi at any rpm or boost level reached.

 

[tufftybloke]

Have you considered an ebc tuffty. Its transformed the power delivery on mine. If your looking for a flatline boost curve you will get it. 4 hours to fit and a great boost gauge too with an aux output to bring on wmi at any rpm or boost level reached.

I have mate but find them cost prohibative at the moment... Bill has a fairly simple one in stock at the moment which I plan to try out and see if its a suitable replacement for an MBC (it is a very simple EBC...)

I like the way the car drives on N75 at the moment and its not really an issue until I get the map sorted anyway... once fuelling/timing/initial boost request etc is sorted then I can look at how much boost my setup will take before there is nothing left to give and take it from there...

What EBC do you have? I like the look of the EVC ones but they aren't cheap...

<tuffty/>

 

[wild willy]

I have mate but find them cost prohibative at the moment... Bill has a fairly simple one in stock at the moment which I plan to try out and see if its a suitable replacement for an MBC (it is a very simple EBC...)

I like the way the car drives on N75 at the moment and its not really an issue until I get the map sorted anyway... once fuelling/timing/initial boost request etc is sorted then I can look at how much boost my setup will take before there is nothing left to give and take it from there...

What EBC do you have? I like the look of the EVC ones but they aren't cheap...

<tuffty/>

I have a turbosmart street boost controller (£230). I would only fit one with a boost correction facility since most i've seen without it will drop boost at high revs since they seem to use only the dialled in duty cycle and not auto modulate it to maintain a consistent flat boost line. Your turbo probably would drop off less at high revs compared to my hybrid, give it a go, there great at elimininating spikes.

 

[IbizaAlex]

...the trim at the front looks as though it will go on too but there is nowhere (currently) to bolt the EGT probe black box and the metal plates bolt holes don't line up with the SEM's mounts for it so I will need to do a little tweaking there too...

<tuffty/>

Its quite easy to modify the bracket to fit the sem. I just welded an extension onto one side then used a couple of riv-nut for the cover to bolt to. There is enough metal to make another dipstick holder too.

 

[tufftybloke]

Cool... will have a faff

Ta

<tuffty/>

 

[tufftybloke]

Managed to get some time on my car this weekend... got her on the ramp so I could change the haldex oil and reposition the DP that was hitting the subframe due to one too many launches ... Anyhoo, I also noticed the inner CV boot had split so ended up changing that too...

Today I put her on the dyno... plan was to see where we were on the revised map... After a few runs we got her up to 352 bhp... this was at around 22psi so pretty happy with that but it was evident that the boost control was a little all over the place so need to work out how to deal with that..

While the car was 'dyno ready' I thought it would be rude not to try the SEM so fitted that on although I am not sure I have made it completely air tight...

Ran up the car and after a bit of tweaking got her up to 374bhp... boost control is still a tad variable and I was seeing 2bar on the gauge driving home so will look into that later...

Some graphs as I have not posted any for a while...

Did a load of logging so going to trawl through that and work out where we go next...

<tuffty/>

 

[wild willy]

Thats an excellent flat line torque plot. Great to see the Sem is doing the business too.
An EBC will flatline that boost delivery completely flat and i mean to within 0.25 of a psi, although your tune is looking pretty good as it is.