I installed Bluefin stage 2 last weekend having had Stage 1 for 8 months without issue.

I also installed a performance downpipe and CAI.

The car ran fine for a couple of days and then I got a CEL while at part throttle in 4th on Tuesday.

This didnt seem to effect the cars performance but i took it easy and after a couple of days the light went out. I am meeting a guy next weekend who has VCDS to diagnose but in the mean time I started having some fun with the car as the light had gone out.

I have just noticed a new issue. When going full blast in 2nd or 3rd I often get hesetations in the power band, really big ones at 4000, 4500 then 5000rpm etc and I can hear the DV actuating a little at it happens, not a full whoosh but a little one like I've backed off the gas.

Does this sound like the dreaded fuel cuts? its not every time but it is often. Or possibly a partial DV fail?

Realising this isnt good, I backed off the testing and set off home. On the way back i overtook a car fairly gently in 4th and suddenly the car had no power, no turbo sound, no DV actuation.....like driving a 1.6 rather than a TFSI.....limp mode?

I pulled over, switched the engine off and restarted....everything back to normal....wierd

I've spoken to SC about the stage 2 map and they are going to update my handset firmware so I can read DTCs with it and they can diagnose. To be honest I'm starting to wish I had stuck with Stage 1 and not bought the extra parts :(

i didnt think the torque bluefin stage 2 produced was enough to give the fuel cuts.

did you go back to the original C revision Dv or are you still on the D revision. Possibly swap them back

Just a quick update on this....I decided to check some key factors that can cause fuel cuts. Checked my cam revision and also the cam follower as per these instructions VWvortex Forums: How to check which cam revision you have...DIY

Took litterally 5 mins. While you cant check the surface of the follower this way, you can at least see that its all in tact and also that you dont have the "A" revision cam.

From what I can see using a torch and a mirror, I have the "B" revision cam and also my follower is in one piece so it cant be that as an issue.

Finally, I decided to go back to the original VAG map and the car drives very well, no fuel cuts, power is surprisingly good (CAI and downpipe installed) and no limp mode or CEL etc

I gave it a very good thrashing with the OE map and all seems good. DV functioning as expected (Its the original "C" valve)

I'm going to send my BF handset back on Monday to get it updated for DTC reading and also aparently the new firmware resets the flash counter to 0 which mine doesnt (mine has old firmware 1.59) after that I can read what the problem is.

I also have a chap helping me with Vagcom next weekend, if it is fuel cuts then I'll need to sort it out with Super chips. Its not horrendous like some people have described it. Basically its like I momentarily backedof the gas even when I didnt. At worst it happens 2-3 times through the rev range.....at others it doesnt do it at all.

I definately got a CEL and limp mode though so something bad is happening.

Ron

think i might send my handset back as well. does it cost?. id very much like to see my flash couner reset to zero. Plus the ability to check fault codes is very useful.

what i find strange though is that you never had feul cut offs when u first fitted the DP, CAI and stg 2. So maybe it might be a fault elsewhere:confused:.

Hopefully they can just adjust the map and sort it though

Hofmiester, have you removed and checked the condition of your fuel pump cam follower recently?

I had fuel cuts before fitting the exhaust system especially in 1st and 2nd gear at full throttle, but after that i didn't have . I don't know if it related with that but if your DV and turbo hoses are allright then the active esp sometimes can cause that problem. Try with the ESP off.

Simon, I'm pretty sure its fuel cuts but it could be a new issue.....however my car only ran for 2 days with stage 2, the CAI and the Downpipe so thats not really a perfect test period. I fitted the parts on a Saturday, then had the issues with the "D" revision valve on Sunday.....drove the car Monday and Tuesday and got the CEL on Tuesday night :(

When I ran stage 2 without the downpipe and CAI it was ok, no issues but then it was no where near as fast as it is now....pulls very hard when it does pull

The Bluefin firmware update is free but they charge £6.50 for return carriage.

Peter, I checked my follower the quick but less thorough way VWvortex Forums: How to check which cam revision you have...DIY you cant see the follower surface this way but by using a dental mirror you can see the overall structure of it and also the cam lobe surface that isnt obscured by the follower. Looks to be ok, the surface may well be worn but it hasnt broken up and the cam lobe looks good so I dont think that is an issue.

I suspect its either fuel cut issues caused by lack of fuel or it could be a very small hole in the DV diaphram that has happened since I re-fitted the "C" valve, the increased pressure may have popped it but as the car drives fine with the stock map, I have doubts :(

Could be something else but the chances of a coincidence like that are slim.

Will keep you updated!

Drkuthan, I had the ESP off....also I got a CEL and limp mode so definately something wrong. I'm surprised the exhaust made yours better as it would use more fuel with increased airflow. Are you sure you had fuel cuts?

I still dont know if what I am getting is fuel cuts, does the description match other peoples findings?

Drkuthan, I had the ESP off....also I got a CEL and limp mode so definately something wrong. I'm surprised the exhaust made yours better as it would use more fuel with increased airflow. Are you sure you had fuel cuts?

I still dont know if what I am getting is fuel cuts, does the description match other peoples findings?

I did have the fuel cuts yes. Esp. in the 1st and 2nd gear at top revs as you mentioned above. At that time i only had the stage 2 software and the CAI, but the exhaust was not installed yet. I had talked to one of my friends who also is a experienced tech and he told me that the causes can be several .

1. wrong launch control (revving above 6500 where turbo dies, missing the 2nd gear)

2. active esp (which cuts of the fuel injection when the wheels are spinning)

3. broken DV (hole in DV)

4. turbo hoses

Hope your problem is not serious and can be solved easily

Hmmmm thanks for the info.....its got me stumped for now....without VAGCOM its a bitch to diagnose. Unfortunately next weekend is the earlyest I can get VAGCOM and thats the same day as the North East rolling road day so it sounds like thats shot for me :(

Option 1 isnt a problem for me as I dont cain it off the line, I'm just accelerating progressivly.

Option 2 isnt an issue as I had ESP off

Options 3 and 4 are possible but the car drives great when running the standard map.

I wonder if the cam follower while apearing to be intact when using the method I used, may have worn thin and so is getting fractions of a millimeter less lift?

I'm going to buy a new follower this week and fit it on Saturday....see what happens. Could be a DV issue but I'm not gona fork out for another one on the off chance, will wait for VAGCOM for that.

Its never easy

Just a quikc update on this. Been driving the car for a couple of days without bluefin and its going fine with no errors.

At the weekend I'm going to check:

Replace cam follower

Check DV

Check boost hoses

Other than that I cant think of much else. I had wondered if it could be a PCV issue? in there anyway to test that?

no idea but if that is the course harry_vRS has an uprated PCV on his vRS

Sill not sure what it could be as last night I got the CEL on while running the car on the VAG map, looks like it’s not the BF stage 2 that’s causing my CEL.

So I have the BF handset coming back to me soon with the DTC reading capability.

Could be a blown PCV or a partial DV fail……could be something else. The car drives fine on the standard map so I may have multiple issues, fuel cuts and something else. I talked to Star Performance and they can do me a pump rebuild with the Autotech parts for £299 + vat

You mentioned that SC now do a map that accounts for the fuel pump too?

Looks like I’m gona miss the rolling road day :(

yes they do do a map, they told me to just make a call to them and they will send the email. said to expect 265-270bhp and 300Ibft torque.

£299 for autotech parts in fuel pump. Im guessing thats using your own pump and them supplying the autotech internals.

im tempted to see how much a new oem pump is and then get that fitted with autotech internals so should i get a problem in the worse case scenario i can swap back quickly

I think the OEM pump is over £250 so thats gona be nearly £600 by the time you factor in VAT with the autotech build. Better to just by an APR (£700 inc Vat) for another £50 as they are bullet proof reliable.

I've got my Bluefin waiting at the Citylink depot so should be able to get the codes tonight and get to the bottom of the problem. Hoping its somthing stupid like a blown DV so i can fix and still make it to the RR day on Sat.

Will see if the fuel cuts are related to the problem or a spearate issue. I dont want to get into chasing BHP numbers, I've been there before and ultimately I spent a lot of money and was always disapointed. If the map is causeing cuts, I may get them to dial it back a bit and leave it at that as the uprated fuel pumps eat cam followers regularly and I dont want any reliability issues.

christ i didnt realsie they were that much more expensive. Do you know of anyone else who would do the autotech internals down south. Star perfoamnce is way out of my area.

interested to see what your fault is though

Good news.....got my fault codes and none are fuel related, I'm pretty sure I know whats gone off here

P0139 : Oxy Sens Circ Slow Response (bank1,sens2)

P1602 : Power Supply (B+) Terminal 30 Low Voltage

P0139 - I have a hunch that this is because the second sensor hole on the Pipewerx DP is blank and so the sensor isnt actually sensing any exhaust gas. Ian at Pipewerx was saying they do this as some tuners running very high end turbos dump more fuel to cool the EGTs and that sets this second sensor off. It seems that my ECU doesnt like it.

Not a big issue as i can just drill the blank through and it should work fine. Not sure why this would cause the car to stutter and go into soft limp?

P1602 - Is a normal code fro when the battery was disconected, which I did when working on the car.

Fingers crossed i can get this lot fixed on Saturday morning and get down to the RR day

On the fuel pump question. Star say they will re-post the pump back the same day as its recieved, i dont live near them either but I think I can fit the pump myself.

If you drill that hole will you not get another ECL flash up. I thought that was the reason it was blocked off.Also i agree i cant see why that would cause it to stutter. I think a RR day would be a good thing as it would show the exact point of the stutter and maybe help with diagnosing a fault.

I dont think drilling the hole is an issue for Bluefin, basically the guy at pipewerx was saying it's left blank for people going for top end power where extra fuel is used to cool the turbo. In ther case of Ko3 tuning, i dont think there is any extra fuel left to add

Also the Miltex and APR DPs dont have a blank hole and they dont get CEL issues either (well they will running a stock map but should eb ok when runnign the remap software)

I have actually found the possible cause of the problems.....Drkuthan metioned he had this problem before adding the full exhaust....then on the SEAT forums i posted this same topic and a chap called (Blade) metioned that he also got this issue on his Leon when running a performance DP with stage 2 but a standard exhaust.

My gut feeling is that its the exhaust but he's bringing Vagcom to the RR day so we can run some data logging on the car and see if I am running low on fuel pressure.

When driving the car today, i hardly got any pulsing issues.....

I just had a bout of spirited driving and i have a 2 small hesitations in the powerband, that were not there prior to fitting my induction kit. Although it pulls very hard before and after. Im thinking it could be a possibility that its the extra air from th induction kit.

GOOD NEWS!!!!

Seems I have fixed the problems...touch wood!

I drilled out the blank on the second O2 sensor and refitted, so far no CEL or DTCs have returned. More interestingly, I also fitted a brand new "G" revision DV and...what a difference! the car seems to pull harder than ever plus the pulses I was getting in the power band are gone. I was actually getting pulses so bad that the DV would actuate but I think it must have had a small hole some where.

I do still get the ocaisional hesetation in the power band between 4500rpm and 5500rpm but its very subtle and also very ocaisional. I can live with it

Lets see what happens at the RR day tomorrow!

result. Looking forward to those results alot. just need the graph to compare with the other ones i posted from the jkm RR day. Where abouts are you going for the RR day

It makes sense to fit a new cam follower when fitting the fuel pump.

It makes sense to fit a new cam follower when fitting the fuel pump.

Agreed, i bought a follower so just need a nice day....maybe tomorrow.

The pump looks to be a fairly simple job, any gotchas Stu?

Simon, the RR day is at Motorscope in Northallerton.....fingers crossed the car wont play up

No real gotcha's to be honest Ron, I always like to make sure that CYL 1 is at TDC although many seem to think it's not necessary.

Make sure not to open the drivers door while the pipework is disconnected, it makes a mess.

Edited 21 March, 200917 yr by VRStu
Spelled your name wrongly ;-)