Help explain what has been modified please

[OZZY]

photo-10.jpg

So I've had the car a week and am just starting to find out where everything is, its hard to start from hot but OK when cold, another member on here very kindly visited me tonight and ran his Elanscan software - basically everything seemed OK. Whilst we were poking around under the bonnet he notice a couple of issues. One is a missing top as you can see in the picture and the other is a disconnected switch or sensor (it is still wired up but not connected to the air intake / turbo diaphragm) one hose is just cut off and the other has been connected with a straight through plastic connector to bypass the unit, this leads from the unit with the missing top to the diaphragm on the turbo. Please see pics attached . We think we have an everest chip but cant be sure, with a piper 2.25" exhaust, K&N filter, ported waste gate and PCE fitted. If this is a mod could someone please explain how it works?

[OZZY]

Here is the other picture.

[esprit888]

This is what controls your wastegate actuator, what kind of (max) boost does the car show at WOT ?

Here is the other picture.

[racerstev]

The 1st picture shows both the EGR valve control and the control valve for the
charcoal canister. Not sure what one is dissconnected there.

Picture 2 is wastegate control. Comeing out of the solenoid you should have 2 hoses.
One goes to the air filter hose the other to the turbo. There are 2 hose's on the turbo,
one goes to this solenoid the other to the wastegate.

[OZZY]

This is what controls your wastegate actuator, what kind of (max) boost does the car show at WOT ?

Here is the other picture.

Sorry I'm not sure what you mean by WOT.

The engine seems fine, the turbo kick in where I would expect it to. Max boost is close to 1 bar and the waste gate seems quite active between gear changes. I am new to these so don't know what is normal.

[OZZY]

The 1st picture shows both the EGR valve control and the control valve for the
charcoal canister. Not sure what one is dissconnected there.

Picture 2 is wastegate control. Comeing out of the solenoid you should have 2 hoses.
One goes to the air filter hose the other to the turbo. There are 2 hose's on the turbo,
one goes to this solenoid the other to the wastegate.

I believe the the one with the missing top is the EGR valve control.

The wastegate control is connected electrically but both hoses are disconnected.

I know nothing about turbos, but I would like to find out what has been done and why, then maybe put it right.

[esprit888]

Sorry, WOT = wide open throttle (also known as foot to the floor, as this is when you get maximum boost) do you have some other form of boost control? (like an MBC which= manual boost controller) because with with your factory boost controller disconnected you should get into overboost where your fuel will be cut off by the engine managment system.

This is what controls your wastegate actuator, what kind of (max) boost does the car show at WOT ?

Here is the other picture.

Sorry I'm not sure what you mean by WOT.

The engine seems fine, the turbo kick in where I would expect it to. Max boost is close to 1 bar and the waste gate seems quite active between gear changes. I am new to these so don't know what is normal.

[OZZY]

I have no other control that I'm aware of. The car used to belong to Chris Jones (he has an orange Exige now) and I'm trying to get a response from him as to why this is disconnected - but not getting any luck.

These turbos are all new to me so I really haven't got a clue what I'm doing or precisely how it works and is controlled. If its been bypassed due to a failing part then I'll get another one and connect it back up. I believe there is a mountain chip in the ECU so I should have the fuel cut off function, but as I said all seems to be working fine, although the wastegate does seem to be very active.

[quote="esprit888"]Sorry, WOT = wide open throttle (also known as foot to the floor, as this is when you get maximum boost) do you have some other form of boost control? (like an MBC which= manual boost controller) because with with your factory boost controller disconnected you should get into overboost where your fuel will be cut off by the engine managment system.

[wayne]

Didn't the BBR kit use a restrictor like this that pluged into the line in the line inplace of the BCFV?

[OZZY]

photo-14.JPG

I had another look today and the BCFV is connected electrically but the airlines are disconnected, the side one has just been cut and about 3" was left hanging off just loose, the bottom one has been disconnected, it looks like its been like it for some time as it is oxidised, by comparison to the one thats left on it looks old.

The air lines that I'm guessing should have been connected to the BCFV are now just connected together.

See the pictures.

I think I have a mountain chip and they insist that the BCFV is not bypassed in any way.

Has anyone got any recommendations as to what I should do? I'm thinking reconnect the lines to the BCFV, can someone tell me which line goes to the bottom connection and which to the side?

[OZZY]

And here are the connected pipes, bypassing the unit.

[racerstev]

Well that's not good.. Just how much boost is the car building?

[OZZY]

Well that's not good.. Just how much boost is the car building?

I will check later today (my seats are out at the moment being refurbished), but its very high, however with a mountain chip fitted it will be up to .98 anyway. I think I'll get hold of some air hosing and try to reconnect it, my issue is I'm not sure which way round the hoses should be fitted. If anyone can tell me I'd be very thankful. I have requested a password for the online manual which might tell me but haven't had a reply as yet.

[wayne]

Before you reconnect the BCFV have a look at the other end of the pipe for a restrictor. see attached PDF

Also look for modified wiring at what they call the "boost sensor" Looking at the location they describe on the bulkhead
I assume this is the map sensor?

BBR instructions.pdf

[JonT]

I will check later today (my seats are out at the moment being refurbished), but its very high, however with a mountain chip fitted it will be up to .98 anyway. I think I'll get hold of some air hosing and try to reconnect it, my issue is I'm not sure which way round the hoses should be fitted. If anyone can tell me I'd be very thankful. I have requested a password for the online manual which might tell me but haven't had a reply as yet.

As shown in the BBR manual Wayne posted (bottom of page 3 - and it's the same in the Lotus manuals), the horizontal pipe comes from the wastegate capsule, and the vertical pipe feeds to the intake. However I'd see if there's the other half of the BBR kit fiddling with the MAP sensor readings before reconnecting the BCFV because if the ECU is being fed incorrect readings, the BCFV won't work properly anyway.

[OZZY]

Thanks for your help, I'll investigate later today.

I'm hoping the previous owner who modified the car will get in touch with me soon and reveal what he's done, that would help solve the few issues I have.

The reason I believe its a Mountain chip thats installed is because I have a bundle of paper work with the car with all of the service invoices etc and in amongst this is the Mountain chips paper work and instruction manuals, no mention of BBR.

[OZZY]

Mant thanks to Wayne for the BBR manual, it's help me identify the fact that it looks like I have a BBR kit installed.........but it also looks like I have a Mountain chip installed too.......

[OZZY]

and here's what looks like the BBR module - the blue box on the right......

[OZZY]

and a restriction in the air line to the airbox.........

[OZZY]

can anyone tell me whether the missing top on this module is associated with either upgrade? If not I'll try and blank it off when I know what it is.....