Hesitation just on boost

[iowa vw]

I've been working on the tuning for the new engine in my Beetle and cannot figure out a few things. I am new to turbos, EFI and Holley so have a big learning curve.

I've been working with CB Performance remotely tuning but we've kinda hit a wall of what can be done remotely. I went to a local Holley tuner, though he's never worked on Aircooled VWs. There are 2 issues I want to get worked out.

1. It runs very rich almost all the time, in the high 10s and low 11s. The injector dataset was used to configure in the ECU. I think I need to update the entire fuel table to pull out some fuel but have wanted to figure out the next issue first.

2. At about 3600 RPM right when I am just getting 1 lb of boost there is extreme hesitation and it goes super lean, 17+. If you just keep it floored it will get through in a few seconds and then it's all the power, ripping the tires lose in both 1st and 2nd. It pulls great all the way to 7800, maybe a little rich at 15 lbs. Haven't turned the boost up because on the dyno we overpowered the clutch/pressure plate. On the street I think I can turn it up. When cruising and downshift so the RPMs are above 4000 then there is no hesitation and it goes straight into boost.

My local tuner thinks the Throttle Position Sensor is noisy and needs a 100uh capacitor to clean the signal. CB Performance has not had that issue. Local tuner also thinks the blowoff valve is getting bad reference from the IAC but I don't see weird readings on the fuel pressure which is connected at the same spot. Thoughts?

I can provide the tune file and catalogs if that would help, let me know. What are you're guys thoughts on the hesitation? Any help is greatly appreciated.

Specs:
Forged internals
2180cc
CNC match ported Intake with injectors
CB Performance CNC Wedge port heads, 44x37.5 valves
Engle FK-10 cam
48mm Throttle bodies - no injectors
Injector Dynamics 1050x injectors
RAD X30-660 turbo
CB Performance hideaway exhaust
TurboSmart wastegate and blowoff valve
Holley Terminator X ECU
3 port boost controller
Kennedy stage 2 Pressure Plate
Dual friction clutch
Custom built intercooler and plenums
Idle air controller from.CB Performance with boost reference for fuel pressure, blowoff and wastegate all connected to it.

First picture is of the idle air controller block and the lines running from it

[Bruce.m]

Got a screenshot of the VE table?

[Bruce.m]

Ah, not sure you get access to that in the software.

When you say it’s going lean at light boost, is that based on what you can see on a boost gauge (independent of the ECU) or what the ECU log tells you. If the incorrect MAP sensor profile was selected that could mess up the ecu reading.

What is the set “offset” for AFR oer 7lbs of boost? (Basic setting)

[iowa vw]

Here's the VE table.

Right when getting into boost is when it goes lean. That is based on the datalog from the ECU, I dont not have a separate boost gauge independent of the ECU. The MAP sensor is setup as Holley 3bar 554-107 with a -12 kpa offset. This was how CB Performance had set it up.


What is the set “offset” for AFR oer 7lbs of boost? (Basic setting)

I am not sure what you are referring to here.

[Piledriver]

One thing that is easy to "miss" can give you a ~dead lean reading is an actual miss... No burn, all the 02 is still present, so those misses show up as free air more or less. Doesn't matter if its too much fuel or a weak or non existent spark....perhaps tighten up your plug gap?

Does the software have the ability to do a retune from datalogs or in real time?
If so, all you need is a hill or a few freeway on ramps, at least up to ~150KPA.
(and a reasonable spark map, and ideally good knock detect/ignition retard, but a conservative spark map should allow you to get your fueling reasonably close)