yes it does - i seem to remember quite a long discussion about this in the past - think the thread was blocked due to alleged " tdi bashing"

the SC makes about .35 bar anyway so no worries there - as there are not so many autos with the sc about ( on this forum anyway) then im not really sure about the raise in boost pressure but i find it surprising as at even max rpm the max is norm 0.35.

where have u got the gauge plummed into?

Thanks very much mate.



When woz mentioned this to me at TDi a thought it was a tad strange.
I thought maybe the Gauege sender needs calibrating? I calibrated my boost gauge at work to check it.

And Yemgi, your reading seem very high. surely the boost cannot really go any higher as the engine cant go any faster so how can the boost go up? thats my understanding of it anyway, i may be wrong.

But i also dont like the sound of lights being on the dash, if this is what you have to have then i think i'll stop looking into the bigger pulley, it just doesn't seem right.

Just my two cents anyway.

Stav

Surely the idle should be fixed then as he has this?

Also he still has the cat as stated on WIM so the engine light shouldnt be up either?

Stav

You would have to ask Steve @ Charlesworth.
The feed goes into an HKS black box (didn't see an adjuster on it)
then to the electrical HKS Boost Gauge.

Wozza,

it seemed when i looked at it to be plummed into the side of the throttle as normal.
iy you open up the little black box that the pipe goes into there will be a little pot to turn and calibrate it, as the box will recieve the pressure signal and send a mA signal to the control box that goes to the gauge.

Stav

Regarding disclaimers I don't think,in law, you can rely on one to excuse poor workmanship/negligence.

BTW I am in no way saying TDI-PLC were negligent or guilty of poor workmanship just pointing out my understanding of things

It can't need calibrating if it reads 0.35 boost under full acceleration though ?
It's when the gear change happens under full throttle the boost goes up.

it was just a thought.
I have the ability at work to do it so thats why i did mine, thats all just to check it.

Stav

Yes, all is managed by the HKS FCON but the standard ECU still has inputs from the sensors and what they show is out of range compared to the standard map so engine management light comes on
Not yet but intake boost is available from the FCON and was 0.3 with the standard setup, is 0.45 with the Katana intercooler and has been 0.65 with the Katana intercooler and the stage 1 pulley

Yes for the idle. The Katana manifold has no cats though and if the car is mapped has mine, it is running slightly rich to be safer

Yemgi, has your car had to pass any sort of MOT ? If all the cars are running rich with the Fcon fitted are they passing MOT

The reason the E/M/light comes on, is that the car is running rich and the 02 sensors will pick this up, then tell the standard ECU, then light comes on, if it was mapped correctly this would not happen as the 02 sensors would pick up the right AFR, thus no e/m/light.

When this was happening to Raj's car, He was told that the sensor was the problem. After fitting to a diagnostic machine, he seen with his own eyes that the sensor was working, even changed for a known working one, and same problem, to much fuel due to not being mapped correctly

My car has to pass MOT in March. It could not pass even with just a standard supercharger, CO emissions were to high. Fortunately in France there are other means to get it
here is my OBD-II report

Firstly Cho,id like to say im absolutely devastated for you bud and that it is 100% genuine.I cant help but feel that you are a complete innocent party in all this,being a paying customer-just as I and many others are.Its the worst time of year to be experiencing difficulty with our beloved motors and its even worst for you as you have lost total usage of your pride and joy,its obvious you are an enthusiast that loves his car.I really do hope this situation is resolved amicably as it was when my car had issues with the same company-I must say they acted very fairly and did resolve it to my satisfaction and the clubs satisfaction.I would like to believe that a full vehicle report could pinpoint the issue and the cause of your problems-however after speaking to an engineer that is building an engine for me at the moment-without certain technical info,it may prove to be impossible to find the offending article or cause.I appreciate that you may feel really depressed at the moment and all i can say is chin up mate,just as many of my friends and well wishers on LOC did when i was having my problems,and hope you understand that this is absolutely genuine,because you remind me of myself a while back,as we are all just regular 9-5 guys that love our cars.( i had little knowledge then and im afraid to admit very little now-but because of this forum I was lucky enough to be guided and helped very well-which i feel helped resolve the issue)

I was going to send you a PM but as I dont know you and havent had the pleasure of meeting you at any point I decided its best to just write it in your thread-hope you dont mind.I appreciate all cars are different and its all he said,she said,this however was the situation I was in and I thought you may like to know about it-considering your car has all the same parts fitted as mine did.
My car was fitted with the TTE sc ,it passed MOT no probs and as usual it never missed a beat,as soon as I had the hks v-pro,injectors,camcon,mapping etc fitted by tdi-my car was over fuelling and when i ran out of fuel on the A50-the RAC blokey put in his diag machine and i had a list of faults,O2 sensor and cats.The car wasnt running correctly and the car wanted to cut out all the time,infact it did a few times.When it was taken to charlesworth,Steve who does MOTs all day long-clearly told me it would NEVER pass under these circumstances.The car was diagnosed as being mapped poorly by three seperate garages(the parts were the best a car could get-but the mapping was out,Lexus also diagnosed poor mapping.I had trc flashing and a permanent engine MGT light on.It was a very scary experience as the car never felt right and after having multiple experts tell me there was something majorly wrong-it does start to make one think if all is well.After multiple trips to TDi i decided to end the project and take all the stuff off and return it to them-in my case the refund was swift and I have to say thanks again to all parties involved.I appreciate you are in slightly deeper than i was,in that your car has suffered from a complete failure-but i do want you to understand that you are supported by the members on here and many will be happy to help ,not just in advice but in any way they can-i know this as i have many friends within LOC that have travelled many miles to help me,taking time out of their schedule and really being 100% helpful.If there is anything I can do to help at this stage then dont be afraid to ask-my tech knowledge is not great but I can help in many other ways.Like i said earlier chin up-my confidence was shattered when i had my issues and can completely understand your mood at this point-try not to be put off for life tho,as its a great hobbie and past time and I think one day your car will be exactly where you want it to be,in the 250hp range.Best of luck pal.

good solid post mr rsarin, well done

sorry to hear this mate, hope its sorted soon.

Ok you can get yours sorted

What about the others running the FCON, How you getting through the MOT with the car running so rich

I'm told IF you get stopped by a roadside check and you don't meet legislative emissions tests then your car is impounded


Again not a dig but a heads up 2 of my cars could struggle

Lets hope there is no roadside check outside JAE next year then

think would be a 50% stop rate !

Quote from TDi in wim
..........................................

Hello Charndrit,

I really am very sorry to hear about this. I can understand that you must be very disappointed.

The IG-FE connecting rod fragility issue is well known and documented. This is the first time we have heard of one of our stage 1 upgrades suffering from this issue, but we do know of engines with significantly less torque than yours that have suffered the same fate, and engines with significantly more torque than yours that have been fine.

Generally speaking, I think it's important to understand that even a standard car will wear out and can brake components, and that elevating the performance of the engine and/or the car will inevitably increase the stresses and reduce the life expectancies, especially if used hard. Some cars and/or engines are much more capable of dealing with increased stresses without further supportive actions than others. There is no "risk free" way of modifying cars, but there are risk reduction proceedures that can be followed.

Generally speaking, when deciding whether or not to undertake any modifications, and choosing who to use, I find that the following processes are worthy of consideration:
1. Ask yourself whether you are prepared to accept the risk of any possible problems that may be encountered.
2. Identify the best possible components.
3. Identify an installer that is competant and professional. I would also advise conducting a credit check on the prospective candidates in case they make a mistake which they are expected to pay for but are without substance.

As I mentioned to you by phone on Saturday, I am as confident as I can be (without an inspection) that the failure is not due to anything that we have done wrong, and that if you have any doubt whatsover about that, that you should seek to have a report done by a suitably qualified independant engineer.

I also confirm our conversation that we could offer you a sympathetic rate to carry out the repairs if you want us to.

If it becomes clear that we have done something wrong that has caused this failure, I can confirm that we are legally and morally liable to repair it free of charge, at the very least.

At this stage it may be wise to consider your possible paths for the engine, so if I may, I have set out the following suggestions for your consideration, although there may be more:
Lowest Cost and Minimal Future Risk
Obtain a used engine and remove the supercharger and all of the high performance equipment, and revert back to the standard specification.

Minimal Cost and Higher Risk
Obtain a used engine and reassemble with the supercharger and other high performance equipment. This is higher risk because you won't know how good the used engine is or how long it will last.

Higher Cost and Lower Risk
Obtain a new engine from Lexus and reassemble with the supercharger and other high performance equipment.

Highest Cost and Lowest Risk
Rebuild the engine using uprated parts and reassemble with the supercharger and other high performance equipment.

I hope the above suggestions are of some value.

Once again, I would like to extend my sympathies to you.

Please let me know privately how you get on or if you would like our help.

With kind regards

Mark Catchpole

So when Cho gets the car running again, is Mr Mark Catchpole going to take the parts back that dont work, re-eng/man/light and give Cho his money back, like he did with Raj.

As for conducting a credit check on the prospective candidates !!!!!!!! i think he means CCJ's against prospective candidates

Ps. i would have posted on WIM, but that silent removal comes to mind

It's comforting to here that TDI will stand by there clients and I would like to thank him for these reassuring comments

Sorry to hear this mate

Agreed..... Asking for an independent report is an honorable step in the right direction.

Gord if you have a complaint about how i run wim/forum please pm me.

Not been around much (out the UK), so just been catching up on this thread.

I would like to add my sympathies and hope you can get back on the road asap.

PS Can TDI not post on LOC anymore? I know they left as a Trader, but are they not still just normal LOC members with the ability to post? Just seems abit unfair of having Wheels-in-motion stuck in the middle as the "voice of TDI"

Hi Anees.... TDi can post without restraint but won't do so here for various reasons.

Cho's issue was also posted in wim and i felt it was important for LOC members to capture the full picture including TDi's reply..

My position is voluntary, i'm not stuck in the middle.... If the post in wim seems valuable to LOC then i will transport it.... If not, not

I did Tony, sometime ago now you never returned it

I did send you an explanation in wim but the exclusion denied you the opportunity to read the pm.... I apologize for that "hands up".

You have a pm.

I was wondering how useful an engineers report is going to be in identifying where the blame lies for the thrown rod in my engine. It seems clear to me after some consideration that surely if there was no problem ever with my car before undergoing the stage 1 conversion it is obvious that it is down to the work carried out being outside the safe limits of my engine. TDI clearly state that a 1G-FE engine can handle 0.5 bar of boost without the need for forged internals and furthermore they only recommend this as part of any further upgrade e.g. stage 2. I don’t believe my engine would have suffered the same fate had I left the car running the standard TTE setup. A company like TTE would have extensively tested there product and it would have been well within the safe limits of the engine. However I don't feel that the TDI upgrade could have been tested to the same level. Surely then it is quite clear that TDI should take some sort of responsibility for the damage. Do I really need to go to the extra expense of having and engineers report done and all the other associated costs?

i'm afraid proving it is the problem.

As simple as it may seem to you there's always an argument that it would have happened anyway upgrade or not.

My own personal opinion is that the mapping/fuelling seemed wrong by the fact the lights were on on the dash and the high idle, also that your opinion may well be right, but i'm certainly no expert and i'm afraid its only my opinion.

Good luck getting it sorted though mate.

Stav

Thanks Stav, TDI are sending me the full map by CD today so this sould be helpfull, they have been co-operative

As Stav has said Cho, I to dont think your car was running right coz of the lights, all of the cars that ive seen from the company that you used smell of petrol, as in running very rich.
The rod could have gone with your standard TTE set-up as it did to Chris s, you just might have had a weak rod Cho. I know you might think different, but when you sit down and think about it, it could of been a weak rod.

I dont know what you still wanting out of your car, but the way i would go is, get myself another engine, get all the eng/man/lights off, you will need to find out what making them come on 1st.

I guess your right mate the thing is I had the car from new and its just hard to believe that having done 69k in it everything was fine and having done in the region of 500 after the stage 1 it died on me. You are right though, it may have been a week rod but that just leaves me with a 1.5 ton paper weight sitting on my drive way.

500 miles doh! and weak rod!

Can't spell!

I want my car to be reliable and fast. I am willing to take my time getting there as the last thing I want is for this to happen again

What im not understanding is, you say you payed £5500 for only 7bhp more than standard tte one.

What sort of bhp was you expecting ?

For what its worth & from whats been posted it seems that the company who did the work are being reasonable.

The mapping data should give an independant party an idea of if that was done responsibly. If the answer is yes then I honestly can't see any mileage in getting an engineers report. If however the boost the conversion was running was over .5 bar things may get sticky.

What I still can't get my head round is why the power gain was so small (7 bhp over Lee Icemans std TTE s/c'd car)

I hold the view that the most bhp you can get from the TTE s/c'd IS2 is 245/250 bhp. Your cars output & Yemgis sort of prove this.

If you want bigger power than that you need to go Turbo or chnage the supercharger to a Rotrex or Lysholm (and do the internals)

This equals big ££££££££££££

If you want the lexus badge and big power theres only one thing to do................rebadge a Toyota Aristo V300 as a Lexus. I'm not being sarcastic. for £5.5k I had uprated suspension and anti roll bars fitted -- boost upgrade -- V Spec intercooler -- 3" exhaust custom made -- and HKS RSK induction kit -- uprated fuel pump easy 400 bhp and handling to match........

Hope it all gets sorted ASAP either way

I gained over 40 hp at the Hubs from the work done

That torque increase was also substantial it made a massive difference to the car

Yemgi has said that his HKS FCON can read the boost that he was running, said so on a post on here.

Can yours do the same, coz if you was running over the safe 0.5 you might have a case.

Here it is...........................

Not yet but intake boost is available from the FCON and was 0.3 with the standard setup, is 0.45 with the Katana intercooler and has been 0.65 with the Katana intercooler and the stage 1 pulley
-----------------------------------------------------------------------------------------------------------
Looks like Yemgi was running @ 0.65 with stage 1 pulley, if yours was running @ 0.65 you should have a very good case, as the company you used knows thats this is to high a boost with standard internals

.65 sounds a little high to me if he's running standard internals????

The light shines

Did you have a pre work dyno and a post work dyno ?

I say that as Lee's car is bog standard IS2 TTE s/c and was dyno'd on the same dyno as yours

Yes I did, the car was running about 153 hp at the hubs before the upgrade.

Can't understand that at all.

Lees car is standard

153 is low as well though with a s/c

gives ~ 185 at the fly.....

seems a little low to me too.

Was the before and after dyno done on the same dyno??

Would have thought so.

I've never known a supercharged IS to make only 153 bhp at the hubs/wheels

would the dyno charts show the A/F, Cho have you pyhsically got the charts.

Yes I have the charts but not with me at the moment, the same dyno was used both times. I don't know if the A/F is on the charts but there is extra info on the back and TDI are also sending me the full mapping output for my car from the dyno.

I don;t think TDi's dyno does AFR from what i remember, or at least on the RR day they didn't attach any Gas monitors to the exhausts to measure the AFR.

Stav