antera309

Thanks once again for all the advice. I'm over at Stealth now and Vince is having a go at mapping it with the MAF connected. I'll let you know how he gets on. After reading most of the the big 103-page forced induction thread, I understand what the advantages of OBD2 are, per-bank injector control etc but switching to the OBD2 injection system (or dumping in an OBD2 engine) is a nasty wiring job on an OBD1 car. Were this not the case, I would have fitted an OBD2 engine right from the outset. If anyone has written up a guide to OBD2-into-OBD1 wiring though, I'd love to see it.

It's not from an imported car, but the engine was from an Automatic. Autos have a different ECU code (although still ending in AG) that Vince had not worked with before. He's going to have another go at mapping it tomorrow, with the MAF connected this time. We'll see how we get on. All I need now is an ISV. I knackered mine inspecting it for faults. Doh!!

Reconnecting the MAF sorted the idle problems on mine (although exactly where that leaves me with the remap I'm not sure). With mine, the idling problems were worse when cold.

Better. Much better. Idle is infinitely more stable, no stalling. Power is still down (as expected with a "safe" map) but delivery is much less lumpy. Gonna hook up the VAG-COM in a mo and take a look at that Lambda reading. Vince was tutting about not seeing my type of ECU before and being more used to working with the 'rado AG ECU (in the MAF-less configuration) so we might be onto something here. Are you a professional tuner, Kev? If not, then you should be. BTW my brake servo has stopped working. The reason is pretty obvious, but is this something you'e heard of hapenning before?

Good idea. I'll try reconnecting it now

I've just fitted the VF-Engineering Stage 2 Supercharger kit to my Golf VR6 (2.8 OBD1) cabrio. The kit includes a Vortech V9-F charger pullied at 8PSi and redtop injectors. Fitting went perfectly but Vince @ Stealth was unable to remap the ECU for the new setup (MAF disconnected). The problems were: - Wildly overfuelling at a given injector time (70% above another VR6 with the SAME INJECTORS and supercharger setup). Lambda reading way too low, even at part throttle. - Fuelling deviating wildly on subsequent RR runs, even with the same map. - Erratic idle. Idles at 1500RPM sometime, other times it stalls. Vince did the best he could with the map, but it only made a (very lumpy) 240BHP (Target was 270-280). On the road, the car will occasionally pull hard like it's supposed to, but then will suddenly stop accelerating so hard, almost like a misfire, except there is no stuttering. Car was fine before fitment of supercharger kit and made 204BHP with just 268 cams, a BMC filter, Corrado TB & the remap. Car is back on standard cams now. Corrado TB remains. Do any of you VR6 gurus know what could be causing these problems? Lambda sensor? Stuck injector? Vince is lost on this one, which isn't a good start :(

Thanks once again for all your help. Here's a pic of the completed install:

Yes, superchaged, my engine needs the chains done and £1500 worth of head work. The manifold is being sold to finance this work. It's a shame because I was going to get the VSR chrome plated and it would have looked seriously trick, but the finances for this project aren't a bottomless pit, unfortunately.

Against all the odds, Vince at Stealth was able to get the manifold working, thanks mainly to Steve (Alfie Noakes) who kindly allowed the flap mechanism on his VSR to be copied by Stealth's fabrication people while his 'rado was in having other work done. Thanks to this, Stealth now have a pattern for building these flap mechanisms so if any of you are concerned about the condition of your VSR's internals, they will be able to sort you out. Many thanks also to Mike (mgbv8mike) and Trev (TREVR6) for their offers of help with this project. For me, the story didn't end that happily though. While attempting to remap the ECU for the manifold, Vince discovered some pretty terminal problems with my engine, including knackered chain tensioners & valve seats. Should have chosen my VR6 engine more carefully, I guess. I've decided to sell the VSR, cams and other tuning bits I've put on the VR6 to help finance a 24v engine swap.

So just to recap, to do an R32/24v conversion on a VR6 the minimum you need is: Engine Engine bay wiring loom wiring loom for clocks (same loom?) ECU Clocks & ignition key (plus transponder ring as well?) Collar for one of the engine mounts (size?) Fabricated-from-scratch downpipe Mk4 fusebox, to use as an adpter for the wiring (good tip, there!) Drive by wire throttle pedal possible remote oil cooler to replace the stock one due to clearance problems. Is there anything else needed? (All Existing VR6 parts, new clutch etc. taken as read.) Air con pump will be coming off, so does this mean I need a custom belt, or will a non-aircon VR6 one do the job? For the DBW throttle pedal, do I just need the pedal and its sender, or will I need the pedal box it attaches to (or a chunk of it) as well?

I've found that AutoGlym "Intensive tar remover" works really well for getting sticker glue off of windows. Especially if you heat the glue up a bit with a hairdryer (or a heat gun on LOW) first.. You should only need to put on and take off with a normal stockinette cloth, but if it's really stubborn, you can use a non-stick pan scourer for the take off.

No I wouldn't expect anyone to pull their manifold apart if it is working OK!! Put simply, the deal is this: If anyone experiences a flap failure on their VSR, they should get in touch with me first. Co-operating with me means that they can get a brand new replacement flap mechanism for less than what it would cost them to get the old one repaired.

That would be fantastic. Perhaps there is someone that you could take it to in Holland who could model it in AutoCAD? We can sort something out regarding costs.

BMW Z8 McLaren F1 Aston Martin Vanquish S Saw an Escort RS Turbo Series 1 the other day. These are well rare now.

I can provide quick VAG-COM fault code scans (16-pin connector) if people can come to me. Location High Wycombe, Buckinghamshire.

I'd love to get a look at the German Cabrio with the VSR. What issue of "The Golf" was it in? Will have to order a back-issue! The manifold arrived today and it looks in good shape, nice & clean. Pictures on eBay didn't do it justice. The cover plate (the bit with "VW Motorsport VSR" on it) is indeed missing, but it's got the Pierburg logo cast into it, so people will still be able to see what it is!! I've heard about another VSR flap failure, this time with the flap breaking free of it's spindle. Fortunately, no engine damage in this case. In response to the queries I've had, I am going over to Stealth this Saturday to get some info on the fabrication of replacement flaps, i.e. likely prices and what materials will be used. If anyone needs any other info, please either PM me or post to this thread and I'll ensure your questions are put forward!!

Good thinking, Kevhaywire. According to posts I've read on Vortex he quite often gets hold of complete VSRs. Even if he doesn't have spares in stock, he may be able to get us the measurements that the machine shop needs. I'll PM and direct him at this thread.....

It was indeed. I just fancied a bit of an engineering challenge!!! £350 sounds cheap, but by the time I get it working I reckon it will cost about the same as a new Schrick, but you can't put a price on rarity! I'm hoping it will be the World's only Golf Cabrio fitted with one.

I have just bought a second-hand VWMotorsport VSR manifold. One of the rare original ones, only 500 made. Unfortunately it doesn't have the flap assembly on it, i.e the plate, spindle & flap that separates the plenum below 4000rpm I have found a couple of machine shops (one through Designa Dubs, the other through Stealth) that are willing to have a go at fabricating one up, but there's no template for such a rare item, so they need to take measurements from an existing one. So far, this is my problem and no-one else's. Then I read these two threads on this forum: http://the-corrado.net/.archive/forum/viewtopic. ... hlight=vsr http://the-corrado.net/.archive/forum/viewtopic. ... hlight=vsr It seems this part is prone to failure. Perhaps not surprising seeing as these manifolds are getting pretty old now and it's a moving part that spends its life being bombarded with high velocity air... Failure involves chunks of metal passing into the cylinder bores, messing up pistons, valves and... ...well, the pictures in the first thread speak for themselves.... There is no source for spare parts for the VSR manifold. The flap assembly from a Schrick VGI does not work with the VSR. Apart from the engine damage, a failure will put another (already rare) VSR manifold out of commission and devalue it for it's owner. Those of you with an operational VSR might want take this opportunity to get a brand new flap asembly made up to extend the life of your manifolds and give some peace of mind. We can get a few of them made up. Any that we don't use ourselves can be sold to American owners, probably for very good money. All that's needed is for one kind soul to lend their manifold to Designa or Stealth for a week or so, so that the part can be copied. Over to you, guys....