Ko4- upgrade boost problems

[Bootsy187]

Where do I start!!

I have a Audi A4 1.8T (B5-99)
I've upgaded the turbo to a ko4-015, put in a race manifold, uprated the injectors to 380cc, de-cat exhaust. k&N 57i, forge re-circ DV.

I've had it on a rolling road but the guy couldn't get it to boost above 0.8bar before it dumps the boost!! not sure where the problem lies)

before all this when the mods where installed it wouldn't run properly so we've added a manual boost controller, but it's still running bad, crap mpg, chugs a bits like the timings out, doesnt start straight away it has to turn over for a few seconds..

the garage couldn't read the ecu either because it was chipped by revious owner and ecu was encripted so i sent it to superchip uk and they removed what they think was a revo chip, so now it's stock, and he still cant read it!!!!!! FFS (£300 chip down the drain), rolling road at 208bhp but it dumps all boost at 0.8bar and only has power after 4500rpm...

totally ****** off with the whole process which has been on running for 2 months.. anyone an expert that can help.. pleeeeeease

[hibbsy21]

If it is dumping boost the DV is at fault. IMO not set up properly?

If it has a rough idle the injection timing is a possible factor in that, and injected quantity, this can usually be adjusted on VAGCOM. You have huge injectors and haven't told your ECU.

as for the power only coming in at 4500rpm. you put a big turbo on an you get lots of lag...however this seems a bit excessive.

Wish i could be more help.

Rich

[Bootsy187]

Thanks hibbsy,

The Cars in the garage today and the guys going to replace the DV to see whats happens to the boost.
when the turbo was initally fitted we had it running around 1.2bar and the power from it was insane from about 2000rpm onwards, but it hardly ever lasted and dumped it, and the car went back into a form of limp mode with no power, then I got the ECU un-chipped so he could tune it and it won't go past 0.8bar. He thinks it might well be the DV or the actuator in the new turbo needs tweaking. but after today we'll find out.

I think in the end im going to have to bite the bullet and take it to http://www.jbsautodesigns.co.uk/ and let them tune it as they do stage1,2,3, upgrades on these cars but i think there remap/rolling road tune was about £650.....

Ben

[hibbsy21]

Also you need to think that the ecu will only be set to X amount or boost pressure. That's where I went wrong with my manual boost controller. Whacked it up an thought yeaa this is great and then it drops the boost an goes in to limp mode cos the car thinks its a bad thing. So in all honesty you might need it mapped and get the boost limiter removed or raised.

Yea actuator will need tweeking. But its very easy to go, hmm I'll stick a bit more boost to it.

Rich.

[hibbsy21]

Also you need to think that the ecu will only be set to X amount or boost pressure. That's where I went wrong with my manual boost controller. Whacked it up an thought yeaa this is great and then it drops the boost an goes in to limp mode cos the car thinks its a bad thing. So in all honesty you might need it mapped and get the boost limiter removed or raised.

Yea actuator will need tweeking. But its very easy to go, hmm I'll stick a bit more boost to it.

Rich.