The joys of modifying cars…

For the past few years I haven’t really done too much work on the S3 since the engine rebuild… she hasn’t really needed anything more than ‘servicing’ but one thing that did need a bit more attention was the mapping… particularly the part throttle and cruise areas where she’s not been fantastic…

I haven’t really had the time or inclination to get back into it.. ME7 tuning can be quite a tricky thing to get your head around especially if you have been out of it directly for a while… biggest issue I had though was the MAF… the MAF is an RS4 item and about the largest you can get… it will easily support the power I have but… MAF sensors are very very fussy about the flow of air across the sensor and realistically the inlet tract on my car is too large and too short to get a decent flow over the sensor without it being disturbed…

I fitted larger injectors recently and we played about on the dyno to give the MAF one last chance… all appeared ok but on driving the car home it actually felt worse… at that point I decided to take the plunge into the world of standalone ECU’s… I had an ECU from a very nice guy in Hungary which was given to Bill to try in a car… so I fitted it to mine…

The joys of modifying cars...

Using this meant I could bin off the MAF sensor and use speed density (also known as VE) tuning… tuning started off by essentially just driving the car and applying the learnt adaptions…
The joys of modifying cars...

The logging from the ECU is epic… it seems to log pretty much every sensor there is and more… you can add other non standard sensors too so for now I have added fuel rail pressure…
The joys of modifying cars...

The joys of modifying cars...

…I also plan to add oil pressure too… the added bonus of these sensors is that it can be added to the ‘limp mode’ configuration and should fuel or oil pressure drop off for any reason then the ECU will go into limp mode hopefully saving the engine…
The joys of modifying cars...

It did however show that my fuel pressure drops off a little too much at the top end of the rev range…
The joys of modifying cars...

not surprising seeing as the intank pump feeding the inline pump is the original one of some 17years vintage lol… so that is due to be changed to a deatschwerks DW65..
The joys of modifying cars...

Sadly I never got a chance to sort due to another component failure 🙁

Pulling out of a junction in first gear and accelerated in first gear… bang!… something gearbox related ‘let go’… nursed the car back home and went out to pick up the rather large pieces that littered the road..
The joys of modifying cars...

Jacked the car up to have a look underneath… not pretty…
The joys of modifying cars...

The joys of modifying cars...

The joys of modifying cars...

Thankfully the damage seems isolated to the transfer box…

I have managed to source a replacement gearbox and transfer box so will clean it up and do a few mods to it to aid reliability…
The joys of modifying cars...

To be honest it was always going to happen… my engine is putting more than twice the torque and nearly three times the power it left the factory with and the gearbox itself is only rated to 270ftlb by VAG… just have to stop launching the car as that is the killer 😉

Other than that the car drives so much better than before and I now have much better control over how I tune…

<tuffty/>

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