[Mk2] [Turbo] Rev2 to Rev3

[joola89]

Hey guys,

I finally got round to doing it.

I managed to swap from a rev2 to a rev3 engine. Fired up first time and runs sweet as a nut. Completly shocked how different the two engines are in terms of hardware and performance.

2 problems though...

1. I'm not built like Schwarzenegger so I'm not able to turn the steering wheel because I've lost power steering. I read a thread something about wires behind the passenger seat??? To do what... I can't remember.

2. Around 5500-5750rpm, it's like I'm hitting the rev limiter... what's that all about? I've got good boost, reset the ECU, no error codes, etc. Don't know where to start with problem solving with this one. Whether in neutral or in any gear, it'll bounce around 5500rpm, so not speed related.

Need help (lol), I'm nearly there...

Thanks in advance.

Also... I've got bits for sale... I've tried numerous times to become a member, i don't know how to register.

[Shmed]

To fix the power steering, there is a black relay in the boot to the right of the ecu that just needs unplugging. Have you changed the igniter to a rev 3? I seem to remember I changed either the igniter or coil to rev 3, otherwise you land up with a lower rev limit.

[djpkins]

As

[joola89]

Thanks for the speedy reply guys.

Tried to locate the p/s relay. There's nothing in the boot next to the ecu. Only a green starter relay and fan control box. Unplugged anyway... No joy. Nothing else, other than the ecu.

Located else where?

Will try swapping ignitor/coil today. Did not think as the two parts look the same.

Thanks again. What a beautiful day to work on the car, slap on the sun block.

[r lee]

lolz

[Shmed]

I'll take a look at mine tomorrow and let you know.

[joola89]

P/S relay located... Looks like this:
http://www.camskill.co.uk/m5b0s610p1180 ... 89_to_1999

Front boot... Not back. Lol

Unplugged both connectors, still no joy.

[Shmed]

PM ryang. He knows exactly what you're looking for (he sorted mine in about two seconds) - definitely in the rear boot to the right of the ecu though.

[jimGTS]

As I understand it...the rev1/2 igniter will limit the rpm to around 6k as the ct26 runs out of puff at this point and just blows hot air...the rev3 turbo is much more efficient and will pull up to 7k+ so the rev3 igniter allows you to rev higher...If you didn't have to change the plug on the igniter ( assuming you still got rev2 loom ) or shave a bit off the side...it's still a rev2 one.

Rev limit is the same on all turbos, 7250rpm.

Doesn't matter what turbo you got on a rev1/2 it will still rev and boost to 7+k rpm

Ignitors are different yep, it just so happens using a rev1/2 ignitor on a rev3 means a lower rev limit. Different resistance specs I guess, hense why it doesn't like it.

[djpkins]

.h

[jimGTS]

Is what got to do with smaller injectors??
(440s will still flow a decent amount of power)

Ct26 runs out of puff high rpms due to it's less than desirable exhaust housing.
That turbo is designed for quick spool and good torque. I don't think making good power at anything more than stock 10/11psi was it's goal.
Hense with raised boost for sure gives good torque, but not a huge gain in power. Most on raised boost will still only see 10-12psi at redline even with the boost controller set at 20psi! It just won't flow that at high rpms.

Ct26 hybrids on the other hand are revised units and don't suffer from this high rpm issue. Tho they do have there own faults namely boost creep. (due to small original wastegate not bypassing enough exhaust gases causing it to creep). If your going to get a hybrid, get one with a single port wastegate conversion.

Others things letting rev1/2 engine down are it's cams, also manifold/tb and of course the AFM and ecu.
Tho it's not to say there bad, just there were improvements made on the gen3.

Fuel injector or pump resistor packs I can't be sure are the same across the revs, but I've never heard anyone needing one to do the gen3 efi conversion.
So think safe to say these are ok to use.

[joola89]

Ignition swapped. Spot on!
7250rpm available now to my disposal.

Thanks guys.

Still no joy with my P/S.
I can hear something whirling too, not sure its the steering pump tho. Definitely was working before the conversion.

[Shmed]

I'll try again to have a look at mine - I went to do it last night, but the boot was full of crap, and then my lad was sick everywhere