5 Year Plan: An introduction, build and resurrection thread

[HUFset]

That was 6 months ago lol.
I went back through my records, and the file I have which matches this description is my original base tune, which was incorrectly set for 3" MAF (at the time I was still running stock MAF housing). This file had some issues that were later resolved as well, so I can't guarantee it will work well. Still interested?

If it has the deletes in it. I bought my car with an FT/Motoza setup and Dave wants to charge me a transfer fee to dial in the tune. I have since removed the SAI, but might just bite the bullet and pay $100 for deletes and to dial in the tune with logging.

[MetalMan]

If it has the deletes in it. I bought my car with an FT/Motoza setup and Dave wants to charge me a transfer fee to dial in the tune. I have since removed the SAI, but might just bite the bullet and pay $100 for deletes and to dial in the tune with logging.

Might be worth it. I can't recall if this one had the proper deletes or not... and I'd bet this tune wouldn't run as well as the one already on your ECU since it was a very early base file from more than 2 years ago.

[Believer]

I just received an updated 3 BAR file from Dave. He noted previously there were portions of the file that the scaling was off, throttle axis to be particular. We have not turned up the boost yet but that's coming.

I'm curious folks opinion on my exhaust. The current system is a 3" HFC to a 3" downpipe. This then reduces into my Borla 2.25" for the rest of the run. Does anyone think the size of my exhaust and that reduction in size could be causing a restriction? I am having this issue where no matter the gear, I get a fair amount of timing pull at 6300 rpm to about 6500 rpm and then it will smooth out for the last 500 rpm or so. It is enough pull that the car feels as if it falls on its face and there is a noticable change in exhaust tone. Boost leaks, ignition components, o2 sensors, MAF senator, coolant sensor are all verified good or relatively new.

Dave asked me to log blocks 90, 91 and 93 to verify timing. I have not sent him the log yet but I noticed while logging my Camshaft Adaptation Phase Position value was a static -4* KW. is this normal? I appreciate any and all input or thoughts on this or how to troubleshoot.

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[ray4624]

I just received an updated 3 BAR file from Dave. He noted previously there were portions of the file that the scaling was off, throttle axis to be particular. We have not turned up the boost yet but that's coming.

I'm curious folks opinion on my exhaust. The current system is a 3" HFC to a 3" downpipe. This then reduces into my Borla 2.25" for the rest of the run. Does anyone think the size of my exhaust and that reduction in size could be causing a restriction? I am having this issue where no matter the gear, I get a fair amount of timing pull at 6300 rpm to about 6500 rpm and then it will smooth out for the last 500 rpm or so. It is enough pull that the car feels as if it falls on its face and there is a noticable change in exhaust tone. Boost leaks, ignition components, o2 sensors, MAF senator, coolant sensor are all verified good or relatively new.

Dave asked me to log blocks 90, 91 and 93 to verify timing. I have not sent him the log yet but I noticed while logging my Camshaft Adaptation Phase Position value was a static -4* KW. is this normal? I appreciate any and all input or thoughts on this or how to troubleshoot.

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2.25 isnt very big but you arent running enough turbo to need something much bigger. The 3" tp/dp is fine.

[Believer]

2.25 isnt very big but you arent running enough turbo to need something much bigger. The 3" tp/dp is fine.

Thanks Ray. I am definitely no engineer so my understanding of gas expansion and this and that is fairly weak.

I just want to get this issue ironed out so I can pull smoothly all throughout the rev range. Here is a log from when this issue occurs. The logs are composed of 2nd gear shifting into 3rd gear and reving 3rd out. Unfortunately this was logged with VCDS so logging levels are pretty low.. If anyone wants to see more data I can gladly provide if that would help hone in on the issue. Today when I return home I am going to retorque my knock sensors to be sure that's correct.

Ignition Angle.jpg

Knock_Voltage.jpg

Ignition_Retard.jpg

[MetalMan]

I just received an updated 3 BAR file from Dave. He noted previously there were portions of the file that the scaling was off, throttle axis to be particular. We have not turned up the boost yet but that's coming.

You probably guessed I would be commenting here, haha.
I've been waiting for Dave to send me a 3bar file for more than a week now (was "on the schedule" for April 26). Yesterday 5/5 he was "just getting to it" and said I should have it later that day or today.
Wonder if he just did this 3bar conversion in batches, and if so hopefully that means mine will come soon too
He's bumping up my boost, should be ~25-26psi and taper to ~21-22psi at redline... that's a full 4-5psi higher than my stock-rod tune.

Really curious to hear how your 3bar file works out if you flash it/install the 3bar MAP before I do.

For your exhaust question, does the Borla have a downpipe you can temporarily disconnect from the rest of the exhaust? And basically just run open downpipe (temporarily) to see if the behavior changes.

GOODBYNAAIR runs the SSAC ~2.3" exhaust on his GT2871R elim setup with seemingly no ill effects. Personally I run custom mandrel-bent 2.5" and wouldn't go any smaller.

[Believer]

You probably guessed I would be commenting here, haha.
I've been waiting for Dave to send me a 3bar file for more than a week now (was "on the schedule" for April 26). Yesterday 5/5 he was "just getting to it" and said I should have it later that day or today.
Wonder if he just did this 3bar conversion in batches, and if so hopefully that means mine will come soon too
He's bumping up my boost, should be ~25-26psi and taper to ~21-22psi at redline... that's a full 4-5psi higher than my stock-rod tune.

Really curious to hear how your 3bar file works out if you flash it/install the 3bar MAP before I do.

For your exhaust question, does the Borla have a downpipe you can temporarily disconnect from the rest of the exhaust? And basically just run open downpipe (temporarily) to see if the behavior changes.

GOODBYNAAIR runs the SSAC ~2.3" exhaust on his GT2871R elim setup with seemingly no ill effects. Personally I run custom mandrel-bent 2.5" and wouldn't go any smaller.

I was hoping you would!

So I flashed the 3bar file last night and drove it today. Everything seemed smooth. We have not upped the boost yet, the next set of logs I send him I am going to request pushing it to what you're running.

The more I think about it and talk with some other friends about the exhaust, the less I think it's an issue. I'm hoping Dave has some more input on what he sees in the knock and timing logs I sent him.

My head has been shaved in the past when I had it rebuilt. Is it possible for that to increase the compression enough to matter? Just trying to think on all avenues here.

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[bmoreS4]

Good stuff man, well done!

[MetalMan]

I was hoping you would!

So I flashed the 3bar file last night and drove it today. Everything seemed smooth. We have not upped the boost yet, the next set of logs I send him I am going to request pushing it to what you're running.

The more I think about it and talk with some other friends about the exhaust, the less I think it's an issue. I'm hoping Dave has some more input on what he sees in the knock and timing logs I sent him.

My head has been shaved in the past when I had it rebuilt. Is it possible for that to increase the compression enough to matter? Just trying to think on all avenues here.

You're running only 93 octane gas, right? He may keep your boost limited because of that... I'm on E85 so pretty much the turbo and intercooling will be the limit.

My guess also is that your exhaust piping diameter isn't a big issue. I'd be more worried about your mufflers being restrictive than anything else, but don't have any experience with the design of Borla mufflers.

[Believer]

You're running only 93 octane gas, right? He may keep your boost limited because of that... I'm on E85 so pretty much the turbo and intercooling will be the limit.

My guess also is that your exhaust piping diameter isn't a big issue. I'd be more worried about your mufflers being restrictive than anything else, but don't have any experience with the design of Borla mufflers.

That's correct, i'm running 93 octane from the pump. Hopefully there is a little more room for upping the boost, i'll have to see what Dave says. I forgot you were running e85, that will certainly make a difference, ha.

I'm also reading through some discussion right now regarding 'phantom knock' - hopefully this will get me directed towards figuring out what's going on.

[Believer]

Is anyone able to comment on the amount of timing he's running on my file? I did some logging last night and he's asking for 15* throughout the midrange and into the upper revs. Is this aggressive? Based on how much timing the ecu is pulling out I'm leaning towards fairly aggressive but I have limited perspective.

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[Believer]

Tackled a few things over the weekend.

I found I was getting some leaks from my injector o-rings so I went ahead and replaced all of them with new ones. So far no leaks!

When I was troubleshooting my perceived fueling issue I swapped in a spare 4 BAR FPR a friend had. Well this weekend I found the part number on his regulator was different than the one that came in our rail. His was from a 20th AE GTI. Since I had swapped his in I had all sorts of odd issues from wonky idle to issues starting the car. When I pulled his out of my rail, I discovered there was no pressure in the rail. I suspect his FPR was either bad or designed differently than ours and was allowing the pressure to bleed out of the line. Once I put a good, proper FPR the hard starts and idle returned to normal.

I also took care of a pinched hard line under the car. I mistook the line as an EVAP line. Cut into it and found out I traced something wrong from the bay - turned out to be the fuel return line to the tank. The restriction was much worse than I realized and since cutting this section out my driveability has stabilized so much.



Next steps are to get Dave some logs because I am not certain the degree to which this pinched return line may have invalidated all prior data.

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[MetalMan]

That timing does sound fairly aggressive. Second gear pull, but keep in mind this is on E85/stock rods/lesser FMIC; generally speaking you should be able to run higher timing on E85 than pump gas



(ignition timing on right Y-axis)

That's crazy your hard fuel return line was so badly pinched. Yikes!

[Believer]

A little update.

I received a new file from Dave on Friday. The boost was increased to ~23 psi. I have not logged on this file yet but that's coming soon. I can say however that the increased boost really woke things up. The torque is much stronger overall.

Tonight I worked on a heatshield for my intake. It was made from an old stop sign I found years ago in some woods by my folks house. I'm excited to do some data logs to see it's affect on my intake temps.











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[B5nDisciple]

A little update.

I received a new file from Dave on Friday. The boost was increased to ~23 psi. I have not logged on this file yet but that's coming soon. I can say however that the increased boost really woke things up. The torque is much stronger overall.

Tonight I worked on a heatshield for my intake. It was made from an old stop sign I found years ago in some woods by my folks house. I'm excited to do some data logs to see it's affect on my intake temps.

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Glad to hear it's running well and that heat shield looks great!

I managed to drive my car for the first time after installing the F21 with the base tune. I love how it makes boost way into high rpm's. So much more fun!

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[Believer]

Glad to hear it's running well and that heat shield looks great!

I managed to drive my car for the first time after installing the F21 with the base tune. I love how it makes boost way into high rpm's. So much more fun!

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Thanks man. Dave is doing your tuning right? He's been great to work with.

Agreed on it being very strong straight to redline. One of the characteristics I've been enjoying very much over the k03 😀



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[B5nDisciple]

Thanks man. Dave is doing your tuning right? He's been great to work with.

Agreed on it being very strong straight to redline. One of the characteristics I've been enjoying very much over the k03 😀



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You're welcome! Yes he is. I need to get my bumper mounted and have my stock midpipe converted to 2.5", and then I'll send him some logs. He tuned my stock turbo on E85 too.

How much boost did you see on the base tune? I was hitting 16 or 17 at most. Probably a really good place to start. :)

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[Believer]

You're welcome! Yes he is. I need to get my bumper mounted and have my stock midpipe converted to 2.5", and then I'll send him some logs. He tuned my stock turbo on E85 too.

How much boost did you see on the base tune? I was hitting 16 or 17 at most. Probably a really good place to start. :)

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My base file was actually 20 psi but this is likely because I have forged rods.

Looking forward to how you like the f21 when it's all turned up

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[B5nDisciple]

My base file was actually 20 psi but this is likely because I have forged rods.

Looking forward to how you like the f21 when it's all turned up

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Oh okay, that makes sense. Me too!

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[Believer]

Alright folks, i'm growing thin on patience trying to troubleshoot this issue and i'd like to ask anyone for suggestions.

The issue is i am misfiring on cylinders 1 and 4 in the upper revs, anywhere between ~5800 and 6600 rpm this can occur.

What I have done so far to try and resolve this issue:

• New spark plugs gapped at .028, .032 and .040" - no change
• At the suggestion of Seerlah, I swapped around my injector harness adapters. Misfires did not follow nor cease
• Swapped injectors between cylinders - Misfires did not follow nor cease
• Swapped brand new coils on misfiring cylinders - no change
• No boost leaks
• Went through all vacuum lines to ensure no leaks
• Fuel pump and fuel filters are basically new

At this point i don't really know what to do. The only thing I can think of is one of our connections from when we spliced in the new coilpack harness is failing or otherwise causing issues with the ECUs connection to the coilpack. I am waiting on pigtails for my fuel injectors to come in so I can be rid of the adapters but being that moving them around did not cause the misfires to move leads me to believe these are not my issue.

Anyone have any thoughts or suggestions on how to troubleshoot this further? Again this issue only happens at full load at the specified RPM range above.

[Dan[FN]6262]

I'm not sure if the graphs that were posted earlier are relevant anymore, but what I would try first is to richen the AFR a little bit, try 11:1 from 5,600-5,700 to redline. More fuel will keep the combustion chambers cooler as well as exhaust gases, manifold, turbo, ect. Cooler is better, means less pre-detonation.

If that doesn't help anything I would request 2* less timing from the same area to redline. Rinse and repeat. If nothing changes then you should be looking elsewhere.

Do you have a datalog that you can post up?

What size MAF housing are you running?

[Believer]

I'm not sure if the graphs that were posted earlier are relevant anymore, but what I would try first is to richen the AFR a little bit, try 11:1 from 5,600-5,700 to redline. More fuel will keep the combustion chambers cooler as well as exhaust gases, manifold, turbo, ect. Cooler is better, means less pre-detonation.

If that doesn't help anything I would request 2* less timing from the same area to redline. Rinse and repeat. If nothing changes then you should be looking elsewhere.

Do you have a datalog that you can post up?

What size MAF housing are you running?

Hey Dan - thanks for taking the time to reply to this.

I will send my tuner those thoughts on richening the AFR and see what he says and also his thoughts on the timing. From my understanding and looking at the logs, and what the timing is after corrections, it's fairly agressive in that department.

I will do some logging on my drive home this evening and get that stuff posted up. Are graphs alright or is a google drive link to the data more preferable? I'm running a 3" MAF housing.

[Dan[FN]6262]

GDrive would be great, then you can run the color script to make it easier to understand.

[Believer]

GDrive would be great, then you can run the color script to make it easier to understand.

Hmm, i'm not aware of the color script. Are you able to tell me a bit more?

[Dan[FN]6262]

When I get home I'll PM you a link to one of my logs that runs the script, and instructions on how to implement it.

It's very convenient, low values are green, high values are red, and the color changes are gradient as the values increase.

[Believer]

When I get home I'll PM you a link to one of my logs that runs the script, and instructions on how to implement it.

It's very convenient, low values are green, high values are red, and the color changes are gradient as the values increase.

That's awesome. As much as I work with Excel I feel I should be able to figure it out but if you're offering I'll definitely take it.

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[SquirrelPig]

I've just read the whole thread beginning to end. Great thread! And even better build. I'm just getting started on my build, probably a year or more before I'm ready for a turbo upgrade though. But reading this has given me such a better understanding of what should be upgrading and planning for in the mean time. I have learned so much. Definitely subscribing! Keep up the great work and posts. Hope you can get your misfire figured out.

[Believer]

Thanks for reading and I'm so very glad you found it to be helpful and informative; this was a goal of creating a thread!

I do believe the misfire to be a result of ignition knock. Waiting on a new file from Dave at the moment.

Hey Dan - if you read this, send me over that color script for my log!

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[Believer]

Dove in to take care of my exhaust leak at the turbine today. Discovered more than I expected.



And the blown out gasket



I'll be replacing the cat with a test pipe some time this week.

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[Dan[FN]6262]

You're gonna love the sound and faster spool a test pipe gives

[Believer]

You're gonna love the sound and faster spool a test pipe gives

I think I will too. And the peace of mind that there is nothing inside to fail. I simply saw an increase in spool after removing all that cell material out of the flow stream.

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[Believer]

Test pipe came in. So classic... Thankfully my neighbor is a retired welder as I don't have time to send it back and deal with all that b.s.



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[Dan[FN]6262]

Email this pic to them and let them know that you're getting it finished, idk if they would pull any void warranty crap because of it.

[Believer]

Email this pic to them and let them know that you're getting it finished, idk if they would pull any void warranty crap because of it.

Good idea. Thanks

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[Believer]

Hoping for some input guys.

Took my cat off to replace it with a test pipe and found this. It was not like this inside of here about a week or so ago.



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[Dan[FN]6262]

Time for a compression check

[Believer]

Time for a compression check

This was my next step today.

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[B5nDisciple]

This was my next step today.

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Any updates? What was the deal with the HFC?

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[Believer]

Any updates? What was the deal with the HFC?

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So I am doing a leak down test right now.

Zero the gauge after air is hooked up. Hooked up cylinder 1, at tdc, and the gauge jumps right to 100% leakage. Hook up straight compressed air and air can be heard in the crank case through the oil fill and dipstick tune. I don't hear anything when I hook up through the leak tester though.

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[Bordom]

Damn. Tough news

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