Engine tuning questions

[methodical_4u]

I just installed a turbo on my 2002 PR5 and i'm having problems getting tuning right. The engine is sputtering like it may be getting to much fuel. Even after the turbo spools up it still does it. The boost is set to go no higher then 6psi and it has only reached 4. Anyone have any ideas? I was thinking maybe the blow off valve needed to be adjusted, but i'm not sure how to do it.... I have no experience with turbos at all, so please don't think i'm a complete idiot. Thanks for any help.

 

[Dimitrios]

Did you install the turbo yourself or did you have a shop do it? If it was a shop, they should have the knowledge/techniques (read: OBLIGATION) to help you tune it. It shouldn't just be turning bolts and out the door you go.

Also, if you had turbo kit, what kit (Flying Protege, etc)?

 

[KzA]

well first off, what are you using for tuning? an FMU? There are alot of people here who have experience tuning with FMUs on this car, especailly the BEGI unit..I'm sure you will be able to find help

 

[Brian MP5T]

I just installed a turbo on my 2002 PR5 and i'm having problems getting tuning right. The engine is sputtering like it may be getting to much fuel. Even after the turbo spools up it still does it. The boost is set to go no higher then 6psi and it has only reached 4. Anyone have any ideas? I was thinking maybe the blow off valve needed to be adjusted, but i'm not sure how to do it.... I have no experience with turbos at all, so please don't think i'm a complete idiot. Thanks for any help.

You will have problems with the blow off valve because it fools the Mas Air into thinking that there is air going into the engine when indeed there is not. The stock set up on the MSP uses a By-Pass valve for that reason. You can add the Mass Air to the positive side like this. It will cure the problem only if the blow off sits between the Mass Air and the Turbo housing...

 

[methodical_4u]

Just showing a pic

Here is a picture of the turbo after install.... it's a TSI kit and has been a total pain in the a**. I think it looks pretty good considering the many problems that I had with parts that were missing, and the directions that may as well have been for a golf cart because of their lack of explantion. Oh well, also check out the valve cover... little polishing job I did myself (yippy)

 

[YP5 Toronto]

well the components...look solid. I see the extra injector setup. What are you using to operate these? How is it setup up? What gauges do you have EGT? A/F? Wideband?

 

[Matthew]

looks like a nice setup. i dont recognize it though...anways, like was asked before how are you managing your fuel? do you have a CEL?

 

[methodical_4u]

I'm using the TSI injector control unit, which i'm not really all that sure of how to work it correctly. I know that The fuel can be adjusted from that, but boost still isn't getting any further then 4 psi. The injectors I wasn't to sure about, a site that I had found had said that one wire from each just had to go to ground and the others weren't supposed to go anywhere... which seemed a bit odd to me, maybe that's the whole problem. None of the injector wires are labeled or the ones from the brain box.

 

[YP5 Toronto]

sounds like a whole bunch of things...including looking for leaks....

The part of the "wiring" for the injectors is wrong...one ground? and nothing else?

to be honest...if you want some serious help from some of the guys in the "know" we are going to need a TON more information that what you have provided.

i would highly recommend NOT boosting.....

 

[methodical_4u]

ok, let me know what else you wanna know and i'll gather it up

 

[Little Beavis]

Need to know how the TSI injector controller is working. Where does it get a signal? How can you adjust it?

Your boost may just be that the 6 psi spring is being fed from the turbo and you've got a decent drop through your intercooler that is losing you 2 psi (for example). You could connect the wastegate to the manifold to increase boost a little bit without using a boost controller. But as stated, until you get the fuel fixed, you have other things to worry about.

Problems at idle (and everywhere else) lead me to believe you have a FPR or some sort and pressure is up to the stock injectors, or your additional injectors are on when they shouldn't be.

Where do you live? Maybe one of us is close by.

 

[methodical_4u]

ok, I'll get all that and post it here tomorrow. I'm to tired to even sit here right now. Thanks for the help, will have more info tomorrow.

 

[Brian MP5T]

Sweet looking set up!!

 

[Brian MP5T]

If I'm not wrong...The tube I highlighted is an emmisiion control. An Exaust reburner. Doesn't this hook to the intake manifold??? If so, There is a massive leak that you have to plug.

I took the entire thing off and stuck a short bolt in the hole near the back of the right side of the engine...

(hi)

 

[mp5jeff]

that turbo looks mighty close to the radiator, how much clearance is there?

 

[Brian MP5T]

He can just get a DEI turbo Blanket... $70.00 or so...

 

[mp5jeff]

yea, i just worried about him puncturing the radiator...as it sounds, i dont think he wants anymore probs then hes getting right now hah.

 

[Little Beavis]

If I'm not wrong...The tube I highlighted is an emmisiion control. An Exaust reburner. Doesn't this hook to the intake manifold??? If so, There is a massive leak that you have to plug.

I took the entire thing off and stuck a short bolt in the hole near the back of the right side of the engine...

(hi)

Wow, didn't even see that! Good find. That needs to be plugged or better yet, plumbed into the piping before the turbo (that will prevent a CEL and still allow it to "function").

 

[methodical_4u]

yeah, that EGR tube was another thing not even mentioned in the instructions. Someone had told me that I could just put a filter on the end of it and leave it. Plus the other o2 sensor is hooked up, but it's just hanging there. If I want to put that into the manifold i'll have to drill and tap it out, the primary is hooked up however. As for the injectors there are 4 brown wires that go to them, none of them labeled and of course 4 wires from the injectors not labeled either so I have one from each of the injector plugs grounded and the other 2 hooked to the brown wires. Does that sound right? This project is beginning to be more trouble then it's worth. Also, I am guessing this is sort of like any other valve, but does the blow off screw have to be turned clockwise or counter clockwise to increase boost?

 

[Matthew]

how about the stock fuel pump? if it was bad, you would have bad idle and once you went into boost it would suck then also.

i know you said too much fuel but maybe its not getting enough. also check possibly for a misfire in one or more of you cylinders. when i washed my engine bay a couple weeks ago i got water in the number 3 cyl. and got just about the SAMe problem you are having. i ended up pulling out the wires and sucking the water out of the cyl. lol. worked just fine afterwards.

im not very knowledgable on turbos, however, those were some problems that i had that caused simliar if not the same problem you are describing.