Lean Fuel Issues after 4k rpm on Revo Stage 2+ Ed30

[illyun]

You know, I can't remember seeing any wiring - apart from the Xenons of course - so doubt the wiring loom was affected.  I do remember it being difficult to get the pipes back in but I checked them and they looked flush and correctly fitted.  Only doubt I have in my head is that apparently, the bottom of the I/C was 3" out of place resulting in the rad fan cutting a coolant hose when the car was pushed hard at Santa Pod - purely because of the acceleration.  My local VW dealer sorted it, but I can't understand how it happenned as the I/C housing was fitted back correctly and checked by trying to move it - gently but firmly - to ensure it wasn't loose. 

I'm probably barking up the wrong tree here as I am trying to pinpoint when and how it could have happenned and naturally, if an amateur (me  ) has been let loose on the car which sortly afterwards develops an issue, then the finger of suspicion points in that direction.  But saying that, I can't see how anything could have happenned to cause the fault.  If the pipes weren't attached correctly and were leaking air, how would that affect things?

[tony_danza]

Am I right in saying that the boost hose connections are the 2 lugs and a U shaped clip type?

I don't know if this helps, but they get weakened by playing with them, thus allowing the connections to pull apart under boost and leak out. This in turn throws the ECU to cock and may be your problem, as Jonny has alluded to..?

I had this problem on my 150PD - you can't seperate them by hand, but a shed load of boost soon forces them and it's very difficult to diagnose.. as you can't go nosing around under there with it on a rolling road trying to replicate it.

Pig of a fault, but re-tracing your steps to last known working configuration (oh, there's the IT in me) seems the next step.

[illyun]

Pig of a fault, but re-tracing your steps to last known working configuration (oh, there's the IT in me) seems the next step.

Yeah, if only I could reboot it 

[jonnyc]

Am I right in saying that the boost hose connections are the 2 lugs and a U shaped clip type?

I don't know if this helps, but they get weakened by playing with them, thus allowing the connections to pull apart under boost and leak out. This in turn throws the ECU to cock and may be your problem, as Jonny has alluded to..?

I had this problem on my 150PD - you can't seperate them by hand, but a shed load of boost soon forces them and it's very difficult to diagnose.. as you can't go nosing around under there with it on a rolling road trying to replicate it.

Pig of a fault, but re-tracing your steps to last known working configuration (oh, there's the IT in me) seems the next step.

On the same lines, did you re fit the OEM O-Rings when you changed the IC. You would have had to fit the O-Rings from the couplers, if not then I think thats worth looking at, I bet that would be the cause of the problem.. If not then Im out of ideas..

[illyun]

Am I right in saying that the boost hose connections are the 2 lugs and a U shaped clip type?

I don't know if this helps, but they get weakened by playing with them, thus allowing the connections to pull apart under boost and leak out. This in turn throws the ECU to cock and may be your problem, as Jonny has alluded to..?

I had this problem on my 150PD - you can't seperate them by hand, but a shed load of boost soon forces them and it's very difficult to diagnose.. as you can't go nosing around under there with it on a rolling road trying to replicate it.

Pig of a fault, but re-tracing your steps to last known working configuration (oh, there's the IT in me) seems the next step.

On the same lines, did you re fit the OEM O-Rings when you changed the IC. You would have had to fit the O-Rings from the couplers, if not then I think thats worth looking at, I bet that would be the cause of the problem.. If not then Im out of ideas..

You mean those slender metal rings that came off the ends of the oem pipes and went onto the S3 pipes?  Yeah, we fitted those.    But I'm wondering if they were fitted properly,but we triple checked them so my mind is probably playing tricks on me... but then again 

[jonnyc]

Am I right in saying that the boost hose connections are the 2 lugs and a U shaped clip type?

I don't know if this helps, but they get weakened by playing with them, thus allowing the connections to pull apart under boost and leak out. This in turn throws the ECU to cock and may be your problem, as Jonny has alluded to..?

I had this problem on my 150PD - you can't seperate them by hand, but a shed load of boost soon forces them and it's very difficult to diagnose.. as you can't go nosing around under there with it on a rolling road trying to replicate it.

Pig of a fault, but re-tracing your steps to last known working configuration (oh, there's the IT in me) seems the next step.

On the same lines, did you re fit the OEM O-Rings when you changed the IC. You would have had to fit the O-Rings from the couplers, if not then I think thats worth looking at, I bet that would be the cause of the problem.. If not then Im out of ideas..

You mean those slender metal rings that came off the ends of the oem pipes and went onto the S3 pipes?  Yeah, we fitted those.    But I'm wondering if they were fitted properly,but we triple checked them so my mind is probably playing tricks on me... but then again 

Yes those, but did you re-fit the O-rings??

[MAT ED30]

ed30 ic

s3


with pipes and clamps

[jonnyc]

ed30 ic

s3


with pipes and clamps

The area that I have highlighted, that shows the connector with the O-ring on the end that you should have removed from the ED30 hoses, and replaced onto the S3 hoses. You can see it if you look carefully, slightly green in colour..

If you didn't do this then I would inform JKM and that will be your issue..

[illyun]

Thanks Mat    Jonny, I put the metal rings pointed out by the green arrows from the old pipes onto the new ones, but left the metal bit pointed out by the red arrow on the old pipe if that makes sense.    

[illyun]

Shyte... let me goto the garage and check that old red pipe to make sure.  I really really hope I c0cked up.. please God..   

[tony_danza]

You just jubilee clipped the new hoses onto the existing bits? I'm guessing there in lies your problem?

I think you need some proper connections, like the ones shown in this picture.

[illyun]

Right, I've got the red pipe in my hand and BOTH.. sod it.. let me get a piccy up.  Heres what I've got:

 

[jonnyc]

Right, I've got the red pipe in my hand and BOTH.. sod it.. let me get a piccy up.  Heres what I've got:

 

Well, they all have O-rings on, which means your car doesn't lol..

As far as I can tell from the previous pics the new S3 hoses dont come with the O-rings, in which case that certainly would be a big problem..

Nice Beetle by the way 

[illyun]

Looks like you guys might have helped solve this    I read the APR manual and when it referred to o-rings I thought it meant the jubilee clips    I DID try and remove the o-rings but they were so stiff that I thought they were part of the pipe and not removable.    I suspected it was something to do with the S3 I/C bodge job that I did.  Hell I have learned a lot from this experience and I'm STILL going to do my own jobs in the future - I now know what an O-Ring is  

[jonnyc]

Looks like you guys might have helped solve this    I read the APR manual and when it referred to o-rings I thought it meant the jubilee clips    I DID try and remove the o-rings but they were so stiff that I thought they were part of the pipe and not removable.    I suspected it was something to do with the S3 I/C bodge job that I did.  Hell I have learned a lot from this experience and I'm STILL going to do my own jobs in the future - I now know what an O-Ring is  

Lets hope, its very easy to check, and very easy to solve if that is the problem! Fingers crossed mate! 

indeed illyun theres only 1 person that can solve this now and its not us lot on a forum 

Hehe..