FAQ's to Common Problems

ISSUE:- The vehicle was not running properly and it's not improved after uploading the tuned file (excluding 'off' files).

Why a Remap Won’t Fix a Poorly Running Engine

A remap can be one of the most effective ways to improve engine performance, efficiency, and drivability – but only if the engine is already in good working condition. Remapping, which involves altering the engine control unit (ECU) settings, can optimize power delivery, throttle response, and fuel economy. However, it’s important to understand that a remap isn’t a repair tool and won’t fix an engine that’s struggling with existing faults or wear.

Understanding the Role of a Remap

A remap essentially customizes your vehicle’s engine control parameters. By modifying fuel, air, and ignition timing, remaps unlock the engine’s potential within safe limits. However, they depend on the engine’s current health and baseline performance.

When a vehicle is already experiencing issues – such as poor idling, hesitation, stalling, or misfires – a remap cannot address these issues. In fact, tuning an engine with unresolved problems may worsen these issues. A remap fine-tunes performance, so if the core components aren’t in good working order, it can’t compensate for underlying problems.

Issues That a Remap Can’t Resolve

Here are common engine issues that a remap won’t be able to fix:

• Mechanical Problems: Issues like worn pistons, damaged valves, or a failing turbo are mechanical in nature and require direct repairs or replacements.
• Sensor Failures: Faulty sensors, like the oxygen sensor or mass airflow sensor, send incorrect data to the ECU, leading to erratic engine behavior. A remap doesn’t bypass or correct these malfunctions.
• Fuel System Issues: Blocked injectors or a failing fuel pump affect fuel delivery. A remap may increase fuel delivery requirements, but it can’t fix restrictions or ensure fuel pressure consistency.
• Ignition Problems: Misfires caused by worn spark plugs or ignition coils can reduce power and affect combustion quality, issues a remap won’t fix.

When a Remap Can Help

The only exceptions to this are when a remap is used to disable specific systems that have already been removed or bypassed due to malfunctions or personal preference. In cases where physical modifications are made, a remap can adjust engine settings to account for these changes.

For instance:

• Disabling Faulty Emissions Systems: When emissions-related components like the DPF (Diesel Particulate Filter), EGR (Exhaust Gas Recirculation), or AdBlue systems are removed or bypassed, remapping can help disable the ECU’s dependency on these systems. However, this is typically done for off-road or competition purposes, as it may not comply with road legality in all regions.
• Adjusting for Hardware Upgrades: When hardware upgrades such as larger turbos, upgraded injectors, or free-flow exhausts are added, a remap can optimize the engine settings to handle these enhancements.

Ensuring Your Engine is Ready for a Remap

To get the most out of a remap, it’s essential to ensure that the engine is in good condition. This involves:

1. Diagnosing Faults: A diagnostic scan can reveal stored error codes or sensor issues that may affect tuning. It’s wise to address these issues before proceeding.
2. Performing Routine Maintenance: Check that all engine components are properly maintained, from fuel filters to spark plugs. An engine that runs smoothly will handle increased power and optimized performance settings far better.
3. Inspecting Engine Components: An inspection of vital components like the turbo, injectors, and exhaust system can ensure they’re ready to handle the optimized demands a remap places on them.

The Risks of Remapping a Faulty Engine

Attempting to remap an engine with existing issues can result in a variety of problems, such as:

• Increased Wear and Tear: A remap generally optimizes performance, which puts more strain on engine components. If these components are already struggling, they may fail more quickly under increased demands.
• Compounding Faults: Ignoring sensor faults or fuel delivery issues may lead to miscalculations in fuel-air ratios or ignition timing, potentially worsening fuel efficiency and drivability.
• Reduced Performance Gains: Ultimately, an engine with faults won’t respond to a remap as intended, reducing the effectiveness of the tuning file and the overall performance gains.

BoostCo Remaps Limited: Quality Tuning for Healthy Engines

At BoostCo Remaps Limited, we prioritize engine health and performance quality. Our team advises all customers to ensure their engines are in good condition before tuning. We offer expert advice to guide you through pre-checks, as well as diagnostic support to identify potential issues before they become a problem.

In summary, a remap can provide transformative results, but only on a healthy engine. Before opting for a remap, address any existing faults to ensure you achieve the best possible results and protect your vehicle’s performance. For more information or to discuss your specific tuning goals, BoostCo Remaps Limited is always here to help.

ISSUE:- I have uploaded a new map and now the car has lost all boost after a short journey (there was a loud pop or bang and then lots of hissing).

The Importance of Turbo Hose Integrity When Flashing Performance Remaps

Flashing a performance remap, such as a Stage 1 file, is an exciting upgrade that can significantly improve a vehicle’s power, throttle response, and overall driving experience. However, performance remaps often increase boost pressure, which places additional demands on the engine’s turbo system—particularly on the boost hoses that transport compressed air from the turbo to the engine. One weak link in this chain can result in a dramatic loss of performance or, in worst cases, complete failure. Ensuring the integrity of turbo hoses before flashing a remap is essential to maintaining reliability and preventing costly repairs down the road.

How Increased Boost Pressure Affects Turbo Hoses

A performance remap typically increases turbo boost pressure, which means that all components within the turbocharging system, including hoses, pipes, and couplings, must handle higher-than-factory pressures. Over time, boost hoses can wear down due to age, heat, and constant exposure to pressurized air. Remapping an engine with a weak or worn turbo hose can lead to sudden failures under increased boost, causing leaks, power loss, and possibly leaving you stranded.

When a weak or worn hose is subjected to increased boost, the pressure can cause cracks, leaks, or even complete separation of the hose from its fittings. This results in a sudden loss of boost pressure, preventing the turbocharger from supplying the necessary air for combustion and causing a drastic drop in power.

Common Turbo Hose Failures and Symptoms

There are several signs that a boost hose may be failing or may not be suitable for the increased demands of a performance remap:

1. Whistling or Hissing Sounds: A leak in a boost hose can create a noticeable whistling or hissing noise, especially when the turbo is under load.
2. Sudden Loss of Power: If a hose completely separates, you’ll experience an immediate loss of boost and power, often accompanied by a loud bang or pop.
3. Check Engine Light: In some cases, a leaking or disconnected hose can trigger the check engine light as the ECU detects a discrepancy in air intake pressure.

It’s crucial to inspect all turbo hoses and fittings before flashing a performance remap to avoid these issues. This brings us to one of the most infamous examples of weak boost hose fittings: the “pancake pipe” found on VW Golf 1.9 PD engines.

The Infamous Pancake Pipe on VW Golf 1.9 PD Engines

Owners of Volkswagen’s 1.9 PD engines, particularly in the Golf models, may already be familiar with the notorious “pancake pipe.” This flattened section of boost piping connects to the intercooler with a clip-on coupling, and although it serves its purpose at factory boost levels, it’s notorious for failing under increased boost pressures from remaps or upgrades.

Why Does the Pancake Pipe Fail? The pancake pipe connects to the intercooler with a clip fitting, and over time, the surfaces of the clip and couplings wear down, creating a loose fit. With increased boost pressure, the worn clip struggles to hold the pipe in place, and under the force of the pressurized air, the pipe can separate completely from the intercooler. When this happens, it results in a loud bang as the pipe disconnects, and the vehicle will experience a complete loss of boost pressure, leading to a severe drop in power.

Symptoms of a Pancake Pipe Failure:

1. Loud Bang or Pop: Upon failure, the separation is often accompanied by a loud sound as the pressurized air escapes.
2. Complete Loss of Power: Since there’s no longer any boost reaching the engine, the car will struggle to accelerate, and performance will drop drastically.
3. Possible Check Engine Light: Depending on the severity of the leak and the vehicle’s sensors, a check engine light may appear due to the lack of expected boost pressure.

Ensuring Turbo Hose Integrity Before Remapping

To prevent failures, it’s essential to inspect, replace, or upgrade turbo hoses and fittings before flashing a performance remap. Here are some recommendations:

1. Inspect All Boost Hoses: Check for signs of wear, cracking, or loose fittings, especially at high-stress points near the turbo and intercooler connections.
2. Upgrade to Reinforced Hoses: Consider upgrading to high-quality, reinforced silicone hoses that are designed to withstand higher boost pressures.
3. Replace Worn Clips and Couplings: Replace any worn or loose clips and couplings to ensure a tight, secure connection. This is particularly important for vehicles with known weak points like the pancake pipe on VW 1.9 PD engines.
4. Consider Pancake Pipe Replacements: For vehicles with notorious weak points, such as the VW pancake pipe, consider aftermarket or OEM upgrade options that provide a more secure fit and are designed to handle higher boost pressures.

BoostCo Remaps Limited: Performance and Reliability

At BoostCo Remaps Limited, we’re committed to delivering tuning solutions that enhance performance while maintaining reliability. Our Stage 1 remaps and other performance files are crafted to ensure safe, powerful gains, but we always emphasize the importance of checking turbo hose integrity before flashing a remap. Our experienced team can advise on any additional modifications or replacements needed to ensure that your turbo system is ready to handle increased boost pressures.

Final Thoughts

Performance remaps can be transformative, but increased boost pressure requires careful attention to turbo hose integrity. Weak or worn hoses can’t handle the demands of a tuned engine, and ignoring these components can lead to sudden failures, leaving you with a car that lacks power and possibly requires costly repairs. By ensuring the integrity of your turbo hoses, especially known weak points like the VW pancake pipe, you can enjoy the full benefits of a performance remap without compromising reliability.

For guidance on vehicle readiness, remap options, and best practices, BoostCo Remaps Limited is here to help. Reach out to us today to learn more about achieving safe, reliable power gains.

As a general rule your cooling system should be in tip top condition before you start asking your engine to produce more power.  More power equals more heat and there is no escaping this fact but all vehicles are engineered with cooling systems that exceed the requirements of the vehicles they are fitted to when in good working order.

If you vehicle runs hot under normal use you should clean the system and check for any missing/broken or sticking parts (like thermostats).  A common problem is missing pump vanes on water pumps (plastic and metal are known to fail over time) so if your vehicle is running hot check these first.

Some performance vehicles are know to have recommended water pump changes every 5 years as a precautionary measure for just this reason.