Throttle body modification

[RobDon]

Well we have some success at long last! I replaced the accelerator pedal this morning and also tidied up the wiring to the MAP sensor, I cleaned the MAP sensor and IAT sensor as well. After doing a TBA I went for a run and it runs 90% normal now! However there is still an issue when it comes on boost, sometimes it's 100% great but other times the boost pressure sputters and it doesn't come on smoothly.

I removed alot of the junk under the intake mani, the N249 and N112 and put inline resistors in place, seems to work really well and the fuel pressure seems more stable as well.

So ... the car is running MUCH better and almost back to normal - thank god - but there is still something not right, either the MAP sensor, the Apexi boost solenoid or the turbo itself. I have a new MAP sensor coming so once that's changed it's down to 2 things.

I'm going to take the Forge 007P apart this afternoon to make sure it's not sticking.

 

[v-g]

I was just thinking back and can't remember you've posted serious issues before. Is this the first major serious issue you've had with the car? Just curious.

 

[RobDon]

Yep, first real problem with the car.

 

[RobDon]

Well I took the 007P apart, cleaned it all out, re-greased it and re-fitted the green spring rather than the yellow, so it opens a bit easier. Doubt the DV is the problem but it doesn't hurt to clean it.

I removed these from under the inlet mani:

http://i112.photobucket.com/albums/n191/robd67/rem1.jpg

With 2 electrical connectors left dangling I wired in a couple of hefty resistors to prevent CEL's:

http://i112.photobucket.com/albums/n191/robd67/rep1.jpg

So far so good - with removing the junk, replacing the pedal and cleaning up the MAP sensor wiring, it has all helped alot. New MAP sensor next, if that doesn't 100% cure the problem, I'll try bypassing the Apexi boost controller. But the car is very driveable now which it wasn't before, so forward progress is being made.

 

[v-g]

http://i112.photobucket.com/albums/n191/robd67/rem1.jpg

Which one is N249 and which one is N112?

 

[RobDon]

N112 is the small one, N249 is the larger one.

 

[RobDon]

Well my car is back to running at full strength again! Not sure what exactly was wrong TBH, appears to have been more than one small issue all at once, but since replacing the accelerator pedal and sorting some dodgy wiring to the MAP sensor, it's running normally again. Removing the N249 and N112 seems to have helped as well.

Having loose, dirty spark plugs can't have helped either, so I'm glad I fitted some decent NGK's and got rid of the Denso's, I'll be having some words with Star as the car was only serviced in January!

I also found a tiny hole in one of the silicone boost hoses, which may explain the loss of boost too. Anyway ... running very smoothly now and back to full power - at last!

 

[Nikk]

Glad to hear its running to its full potential again

 

[andycupra]

glad its back to pull working order!

 

[DPJ]

Are you using the 'new' throttle body, Rob?

 

[v-g]

Good to hear!

 

[RobDon]

No, back to the standard throttle body, I've sold the modified one, I'm just glad to have it running again TBH!

 

[RobDon]

Oh well, it's NOT running right!

Can anyone take a photo of their MAP sensor connector plug so I can see the colour-coding on the wires to see which wire goes where please? When fitting the new plug I may have plugged the wires in wrong!

 

[DPJ]

Rob, Have you logged it on Vag-Com to see what boost readings you're getting?

 

[RobDon]

These are the fault codes that I got this morning:

Thursday,22,May,2008,14:40:18:39851
VAG-COM Version: Release 704.1

Address 01: Engine
Control Module Part Number: 06A 906 032 HN
Component and/or Version: 1.8L R4/5VT G 0002
Software Coding: 11510
Work Shop Code: WSC 13622
Additional Info: VSSZZZ1MZ2R043388 SEZ7Z0A1335760
8 Faults Found:

16622 - Manifold Pressure / Boost Sensor (G31): Signal too High
P0238 - 35-00 - -
16490 - Manifold / Barometric Pressure Sensor (G71) / (F96): Implausible Signal
P0106 - 35-00 - -
17705 - Pressure Drop between Turbo and Throttle Valve (check D.V.!)
P1297 - 35-00 - -
16795 - Secondary Air Injection System: Incorrect Flow Detected
P0411 - 35-00 - -
17535 - Fuel Trim; Bank 1 (Mult): System too Rich
P1127 - 35-10 - - - Intermittent
16684 - Random/Multiple Cylinder Misfire Detected
P0300 - 35-00 - -
16685 - Cylinder 1: Misfire Detected
P0301 - 35-00 - -
16686 - Cylinder 2: Misfire Detected
P0302 - 35-00 - -

Readiness: 0000 1101

????????????????????????????

 

[DPJ]

These are the fault codes that I got this morning:

Thursday,22,May,2008,14:40:18:39851
VAG-COM Version: Release 704.1

Address 01: Engine
Control Module Part Number: 06A 906 032 HN
Component and/or Version: 1.8L R4/5VT G 0002
Software Coding: 11510
Work Shop Code: WSC 13622
Additional Info: VSSZZZ1MZ2R043388 SEZ7Z0A1335760
8 Faults Found:

16622 - Manifold Pressure / Boost Sensor (G31): Signal too High
P0238 - 35-00 - -
16490 - Manifold / Barometric Pressure Sensor (G71) / (F96): Implausible Signal
P0106 - 35-00 - -
17705 - Pressure Drop between Turbo and Throttle Valve (check D.V.!)
P1297 - 35-00 - -
16795 - Secondary Air Injection System: Incorrect Flow Detected
P0411 - 35-00 - -
17535 - Fuel Trim; Bank 1 (Mult): System too Rich
P1127 - 35-10 - - - Intermittent
16684 - Random/Multiple Cylinder Misfire Detected
P0300 - 35-00 - -
16685 - Cylinder 1: Misfire Detected
P0301 - 35-00 - -
16686 - Cylinder 2: Misfire Detected
P0302 - 35-00 - -

Readiness: 0000 1101

????????????????????????????

Yes, it rather obviates the need to log. Sorry, mine's not accessible by camera.

 

[PhilW]

You still running 2 dv or a blow off valve?

 

[RobDon]

Forge 007P on it's own on the coldside.

 

[RobDon]

My car is booked in to Star to get this solved next Thursday. Do you think sending the injectors off to be ultrasonically cleaned would help?

http://www.injectorcleaning.co.uk/post.htm

 

[ibizacupra]

Well I took the 007P apart, cleaned it all out, re-greased it and re-fitted the green spring rather than the yellow, so it opens a bit easier. Doubt the DV is the problem but it doesn't hurt to clean it.

I removed these from under the inlet mani:

http://i112.photobucket.com/albums/n191/robd67/rem1.jpg

With 2 electrical connectors left dangling I wired in a couple of hefty resistors to prevent CEL's:

http://i112.photobucket.com/albums/n191/robd67/rep1.jpg

So far so good - with removing the junk, replacing the pedal and cleaning up the MAP sensor wiring, it has all helped alot. New MAP sensor next, if that doesn't 100% cure the problem, I'll try bypassing the Apexi boost controller. But the car is very driveable now which it wasn't before, so forward progress is being made.

I junked these last night and reworked the pcv (removed it) and the engines far smoother and consistent now. way too many vacuum pipes of varying levels of degredation to want to live with.
solenoids remain connected so no hot resistors to be concerned about.