Sounds like your diaphram has a hole/tear in it,pipe pliers increased your pressure just enough to make it open a bit more!
Nick S4s

What is your intercooler temp?

If the chargecooler pump is not working the ECU will limit boost to .65. Does chargecooler box feel warm?

While on boost what does the knock sensor say on freescan?

Also any attempt to adjust the wastegate capsule and if the rod turns/rotates instead of the adjustment nut the diaphram attached to rod will tear.

Calvin

Can't see it Dave. Not a member.

Dr.Hess

IAC replaced and set up correctly along with fuel filter.
Seems to have cleared my cold start problem and runs a lot smoother.
still got the stumble at very low revs but im not too bothered about that.

Just got to try and sort the low boost now.
suspecting the EPROM chip. Every reading ok and no leaks or blockages were ther shouldnt be.
might try a chip upgrade to prove a point.
im presuming if there is something limiting my boost to 0.85 it will still do the same with a higher boost chip.
if it runs up to 1.2 bar on a puk 11 chip then all is ok.

will keep posted

dave

thanks for your input but the last post i put doesnt really refer to your comments.
as only a lotus esprit novice and lover and not a technichan i can only use knowlege i have to fault find. test that have been done so far have proved points and helped me identify faulty components/areas.

dave

hi

thanks for the post.
I didnt know at the time when i originally posted this topic how the turbo system works on these cars but now do.

this is what i am getting and what i understand:

0.65 bar with the wastegate solenoid disconnected (correct as far as im aware)

0.8 bar with the wastegate solenoid connected in closed loop mode with 75% or greater throttle (i can get 100%) and above 5000 rpm giving me WOT (wide open throttle)

I should be getting 1 bar at WOT. This is acheived by a 12v square wave form pulse fed to the wastegate solenoid. in effect opening and closing it to acheive the desired/correct boost. i.e: at the the moment 0.8 bar

I have confirmed there are no leaks from the wastegate solenoid by attaching up to 1.5 bar pressure to the solenoid and energising it (appling 12v). there are no leaks at all and is opening and closing as sweet as a nut with the supply connected and disconnected. so that rules that out.

There are also no leaks on the plumming from/to the turbo.

The actuator is brand new as the old actuator was only giving 0.45 MAX with it adjusted fully and the wastegate solenoid disconnected.
As i said i am now getting 0.65 bar with no wastegate solenoid connected which is correct.

There are no imperfections on the internal wastegate in the turbo and is closing 100% with no leaks.

THIS IS THE PART WERE PEOPLE THINK IM SLIGHTLY BONKERS I THINK. THE REASON FOR RESTRICTING THE PRESSURE TO THE ACTUATOR CAPSULE WITH THE WASTEGATE COMPLETELY CLOSED/SEALED OR DISCONNECTING THE HOSE FROM THE ACTUATOR WAS TO SEE IF THE TURBO WAS CAPABLE OF GIVING ME THE 1 BAR BOOST I SHOULD BE ABLE TO GET OR OVERBOOST. I PERSONLY DONT HAVE ANY OTHER WAY OF CHECKING TO SEE IF THE TURBO IS EITHER LOW PRESSURE/WORN OR HAS A FRACTURE IN THE CASING SOMETHING LIKE THAT.
But anyway i can get over boost with the hose off therefore i know the turbo is ok.
This makes sense to me and rules another part out of the equation if it doesnt to anyone else.

So now i know the turbo, waste gate, actuator, plumming, and waste gate solenoid are ok im on to faulty sensors or reading being given wrong to the ECU.

BUT:

TPS 0.7V - 4.5V AND GIVES 100% AT WOT
MAT AT A CONSTANT 30 DEG C
NOT SHOWING IT IS RUNING LEAN
BARO OK
INTEGRATOR OK
MAP GETTING TO 2.1 BAR (CONFIRMING THE 0.8 BAR SHOWN BY THE BOOST GAUGE)
IAC SET CORRECTLY (STARTS 170 WHEN COLD AND 35-40 WHEN AT 82 DEG AND AT IDLE SPEED 1050 RPM)
NO KNOCK COUNTS
IGNITION NOT BEING RETARDED
Coolant temp at 82 deg c

As you can probably tell i have free scan. i cant remember all the values or sensors but i have checked them all over and over again and Dermot has also confirmed for me that all is show 100% on free scan.

Items replaced that either needed replacing or were faulty:

Spark plugs (NGK)
Magnecor ignition leads
Fuel filter
TPS sensor
IAC valve
Air filter K & N ( RAM induction mod)
Larini twin exit sports exhaust
Cat convertor definately not blocked (ok)
Actuator
Rubber elbow joints on fuel vacume pipes (cracked and leaking)
Oil catch tank

I know some of these would have no effect on the fault but there just there so people know what i have done.

There are also plenty of more bits ( 3k worth) just cant bring them all to mind

Therefor my personal conclusion on all this would say that there is a problem with either the ECU, MEMCAL or the EPROM in the MEMCAL.

If i had to take a guess i would say the EPROM is corrupt.

I repair washing machines and telvevisions for a living so i know all to well how these items can fail.

This is what im thinking: Chip the MEMCAL to prove if there is a gremlin that i cant find still causing the ECU to limit the boost to 0.8 bar. If i get over 0.8 bar then i have prooved that the EPROM was faulty or just not programmed to give above 0.8 bar.

THE END


sorry for the essay guys and i do apreciate the help at all times. What ive said makes sense to me and this is how i think my setup is working, if im wrong im wrong but ive tried specialist lotus garages and they get no where too.

Ill wait for the thousand of replies lol

Dave

hi

yer i know it wont tell me that the rest of the system is ok but it at least tells me the turbo its self is ok. it must be if it can over boost.

would have thought if it was the relay lazy the ECU would work the wastegate solenoid harder to try and produce the 1 bar and compensate for it, up to a point were if it had to, it would keep it closed more to give the correct boost. Or am i not making sense?

where is the relay situated by the way?

cheers
Dave



>> Edited by DAVES_GT3 on Saturday 23 July 17:52

DAVES_GT3 said:

update! is it possible that the boost could be limited if the ecu thought the clutch was slipping. think it is slipping slightly when in over boost but im not 100% it seems the boost is getting lower after running it for 300 miles or so after an ecu reset. it is reaching 0.7 bar now at WOT but the 0.65 bar is is still there when the waste gate solenoid is disconnected. its as if its learning a boost curve for max 0.7 bar. i can get 1.1 bar approx if i go into over boost (revved when stationary over 5000 rpm then pull off) only in first though gone through the whole freescan thing and verything is reading 100% and no codes actuator is new and set ok any ideas? dave >> Edited by DAVES_GT3 on Wednesday 3rd August 21:43 >> Edited by DAVES_GT3 on Wednesday 3rd August 21:45

ECU does not know or care about a worn clutch.

I think you are on to something with the ECU control of the wastegate capsule. It sounds like it is opening it for no reason. Since you show no ignition retardation... If the ignition were being retarded then you wouldn't be able to build the boost. But you also disproved that when you took away the wastegate control and got overboost.

Try swapping with another GT3 ECU. Then try swapping just the Memcals.

You did make sure you have no leaks in the manifold right? Including the one way valves from the crancase breather and the charcoal cannister?



Travis
Vulcan Grey 89SE
www.lotuscolorado.com/vulcangrey/

definately 100% all values are correct as showing on freescan

ill be buggered if i can think of anything else it can be. ive even had dermot on the case.

[U]heres what ive got[/U]

TPS VOLTAGE 0.7 AT IDLE AND 4.5 AT WOT
TPS 0 - 100%
AVERAGE 1050 RPM WHEN IDLING WARM
O2 SENSOR FLUCTUATIN AS IT SHOULD (BRAND NEW)
RICH/LEAN COUNTING 0-256
INTEGRATOR 128
BLM FLUCTUATES 97 - 128
BLM CELL 19
IAC WHEN WARM 30
BARO 0.83 - 0.84
AIR FUEL RATIO 10.9 - 14.6
MAP 2.1 MAX SHOWING THE LOW BOOST ( 2.24 WHEN IN OVER BOOST)
MAT V 3.1 - 3.9
KNOCK RETARD CONSTANT 0
KNOCK KOUNT VERY OCCASIONALLY 1 (BELIEVE THIS TO BE VERY HEALTHY)
BAT VOLTAGE 12 - 14
ENGINE LOAD 5 - 100
SPARK 0 - 74.9
COOLANT TEMP AVERAGE - 82 DEG C
MAT - AVERAGE 29
WASTEGAE DC - 0 - 100
SECONDARY INJECTOR DC - 0 - 9

ACTUATOR SET AT 0.65 BAR WITH THE WASTEGATE SOLENOID DISCONNECTED ( BRAND NEW ACTUATOR)

FREESCAN SHOWS 2.24 ON MAP WHEN IN OVER BOOST WHICH IS 1.1 BAR OF BOOST SO THE WASTEGATE SOLENOID AND TURBO ARE MECHANICALLY OK.

NO RESTRICTED AIR INLET, EXHAUST, OR VACUME HOSES


NEED I SAY ANY MORE?

suggestions would be welcome as this problem is doin my nutt in

Dave

Thanks for the reply

Unsure about the faulty wiring but i will check it.
i presume i will trace it back to the ecu.

someone did say to me it was driven off a relay but i wouldnt see the purpose in having one because the signal the ecu sends out is a 12v square waveform. i.e: on and off, with the time base adjusted via the ecu depending on how often it requires the wastegate to be open (opening and closing the wastegate quicker or slower for longer or shorter periods)

was unsure how to explain that one so it may not make any sense.

thanks
dave