What followed was an interesting few days!
The Turbo arrived back on Thu, having been subjected to a near overnight turn-around (again massive chuck-up to Paul and Turbo Clinic on this one), so on Wed I put the Stock Map back on and cleaned, re-oiled and installed a Pipercross filter I'd had sitting around for ages now.
Once I had the Turbo back I managed to get it in without too much fuss (it's getting easier having had to do it a few times now, and the mounting points were a lot easier to line up now that I had the correct Turbo). No photos as I was under the car and fighting to get it done ahead of the rain - which I managed, just!
Once on it drove OK - even on the Stock Map with the hybrid fitted - a result. This means that I can run any of the maps I have on the Hybrid without issues or having to swap back to the old turbo.
Then, on Fri, I drove to Celtic Tuning to get the mapping done. The plan was to install their Stage 3 map, which has already been used by a few on here...
On the way I noticed the stock map seemed gutless, but assumed I was used to various stages of map. Plus I know the EGR valve is not good, so assumed that it was robbing a bit of power.
On arrival the car went in and I watched the initial runs and the mapped runs on the dyno. Immediately it became apparent that things were not right. The stock map (blue on the plot below) was underpowered and had a massive dip in both power and torque. Again I assumed it was the EGR, but, when it was blanked off and the Stage 3 installed it didn't look too much better (Orange Plot below):
As you can see, not too impressive. I spoke with the bloke behind the desk who said the mapper had put it down to Air/Fuel issues, but I had only put a new MAF sensor on a few years back and it had run the previous Stage 2 EGR off map fine... until I had installed the Turbo - so that was where my suspicions were firmly set. The thought of taking it off again and trying to get to the bottom of it all was NOT filling me with joy - I thought about jacking it all in and moving on to the next project (been doing some reading up already...
) and was generally a bit teed off. Especially compared to what it should have been roughly getting (taken from Celtic's website):
At home, I compared the plot with the one when I had a Celtic Stage 1 installed, as it was the same company and Dyno:
As you can see then my stock plot was really good, and the Stage 1 was excellent, with a really smooth curve and good power/torque.
I then produced a comparative trace comparing both power and torque on:
- Light Blue
Original Map with Hybrid
Celtic S1 Map
Celtic S3 with Hybrid
Celtic S3 Example Map
- Dark Blue
As you can see, my two Hybrid plots were horrific - significantly outperformed by my old Stage 1 map on the stock turbo and light-years behind the example Stage 3. Note the slight lag in all the Hybrid maps from stock, though - you can see it just takes a bit longer to get into its stride and shifts the power quite high into the rev range... Completely what was expected, but interesting to see the differences in how the remaps differ from stock.
By now I was sure the turbo was at fault (probably from me cocking up the install or something similar) so decided to go back to Celtic, get a refund, refit the spare turbo and dig into the Hybrid fitment etc a lot more before deciding what to do next. This was compounded by the car going into limp mode three times before I could get it back to them. Just in case I stripped out the Pipercross filter, as it was the only other change I'd made, but there was no improvement.
So! On Sat just gone I returned to Celtic and showed the actual guy who mapped my car the plots above. We then had a long chat where he said that during mapping the turbo had barely broken a sweat, so he didn't think that was the issue (phew!
). Likewise AFR stayed fine, if a bit lean, so it wasn't a fuelling or airflow issue (likewise
He then went into more detail about the Mass Air Flow issues he had been fighting on the day and again said that he thought it was MAF sensor related. I'd done a bit of reading on this the night before, so asked whether the filter oil could have contaminated the MAF? Although Pipercross refute that this is an issue there is lot of results on it when you look online. He agreed this could be it, and that they don't generally oil PC filters for exactly this reason. I therefore decided to swap out the MAF sensor before committing to getting a refund.
Before I left, Celtic checked the codes for why it had gone into limp mode and found fuel rail pressure had been fluctuating. Basically, Stage 1 and 2 maps generally don't need more fuel (apparently), whereas Stage 3 does - turns out my fuel pump is tired and therefore straining a bit to deliver what's asked of it now. The map's top fuelling was tweaked to remove this issue, losing a bit of power at the top end, until I get a new fuel pump fitted. Overall, I was happy with the service given and the guy I spoke to (Cameron IIRC?) was a top bloke.
On the way home I bought a used MAF on eBay, which will arrive next week, but before then, decided to clean the MAF (had some sensor specific cleaner handy anyway). There was a noticeable deposit of 'stuff' on it and the cleaner only got some of it off. I then (carefully) rubbed the rest off with tissue and it proved to be a grey oily substance... hmmm!
I finished by thoroughly cleaning and wiping the MAF housing and Air Pipes, re-installed it, reset the map and took it out for a drive...
All I can say is that it's definitely putting out a LOT more power and has only got better when I took it out today for the 0-60 comparisons:
Around 7-8 seconds to 60 ain't bad - especially with the need to change gear again just before 60mph!! I suspect if I spent a bit of time working out the shift points I could get that a bit lower, but I was trying not to rev it to the max, avoiding the power drop later in the rev range...
While I will get a dyno test done early next week to check, I suspect it's putting out more than the old S2 map at the least - performance on the motorway when on the move is very good!
More to follow...