My Controller woes......

MGordon · 09-09-2008

A little background.. I have a 2000 Stage 3 Audi S4, located in Calgary AB... I have the 'VAST Performance' version of your kit..

Since I got the kit.. I've really had nothing but problems. I'm currently on my second controller.. and re-did the full install for the second time, and seem to be having the same problems.

So for the first controller.. I used the posi lock for the MAF wire, and it didnt read accurately or get to full pump. I re-did the entire install with soldering the MAF wire, and now the green would come on accurately, but then go off at full pump, and only the yellow would stay on. (I also tested the pump and it was fine)

Vast got me another controller, and after the intial install the lights work as they are supposed to.. green comes on accurately, then stays on with yellow at full. New problem? I'm not getting anything injected! The lines are dry...
So.. onto today.. I re-do the install all over again for the XXth time..(Start with puling the fuse) Pump is covered in blue grime... so Im thinking its done. Nope! Works fine. (tested with water to power source) Re-did the ground, checked all the wires.. and Im hoping for the best..
Start up is normal (two blinks, then 3 fast ones) get to starting point, green works.. get to full and green light once AGAIN turns off! WTF?!?!?! Get home and check the lines.. dry once again.

Please help me... Im extremely frustrated.. and ready to throw this damn thing into moving traffic. I really dont know what else to do.. My ground is bolted right to the chasis (sanded again today to make sure), Power is to an extra terminal, maf wire is soldered, pump works..

Mark

Rocket468 · 09-09-2008

I am not actually familar with the controller being hooked up to the MAF sensor on the audi. It should be a 0-5v item. The controller is designed to be hooked up to a 2.5 bar map sensor. Might try hooking it up to the MAP sensor.

When you apply 12v to the pump fluid is coming out of the nozzle?
Whats covering the pump in blue grime?

MGordon · 09-10-2008

Sorry, my mistake, it was on the MAP sensor wire..

When I hooked up the pump seperately, I placed the intake hose in a bottle of water, and it pumped the water out of the bottle.. So I am fairly certain the pump works.
The blue grime would be from the washer fluid, although Im not certain as where its leaking from... but its leaking from somewhere!

dvldoc · 09-10-2008

Try this, First touch the grey wire to the green wire with the map sensor unpluged. You can use your left over posi connector to due this task. Make sure the hose is disconnected from the nozzle assembly, Let the system run for at least 10 full seconds on full. All light should come on the controller when the key is in the ignition on position. This is to clear any air out of the system. If there is air in the lines then the pump cannot clear it past the check valve and the system will stop working.

Second check all your hose connections. If you have a leak this means your getting air in the system. Make sure all hose ends are cut strait with no angles on them. This can cause them to leak. Also no major bends or kinks that could be pulling the hose to the side.

Also on some vehicles the ignition source wire is not up to the task of running the controller. Adding a relay will cure this little demon.

MGordon · 09-10-2008

And I thought it was interesting before.....

So I get all the wires ready.. and first time I tap the into the green.. a fuse goes.

So I replace the fuse, and turn the ignition on.. grey/green arent connected.. and I have full pump!
What the shit?!? So I try a different fuse.. same thing. Even try connecting the wire while thats happening.. doesnt make a difference.
So Im guessing this controller is fubar'd.. Luckily I missed the mail today so I am gonna try the old controller I was going to sen back to see if that works...

On top of all of this... there is a major leak coming from the pump. My pump isnt readily accesible or in clear view so I cant see where its coming from...
Im going to have wait till friday to rip the bumper off and take a look at the pump...

MGordon · 09-20-2008

Following up...
1. Pump leaking.. One of the screws was loose on the top of the pump.. tightened and not leaky anymore.

2. Constant pumping.. Still doing it! Whether the MAP is hooked up or not I get full pump.. Tested with a volt meter and get the exact signal at the controller as I do the actual MAP sensor.. so would that be the controller? Or maybe part of the pump? I saw another post where the pressure switch was bent and causing the pump to be on 100%? Where can I check this?

Thanks!

Mark

MGordon · 10-14-2008

Any help with this guys? Its been a few weeks that I have waited patiently.. I would love to get this kit running before winter.

dvldoc · 10-14-2008

have you opened the controller to make sure you don't have a stray wire touching in there? The controller only knows voltage you need to let us know what voltage your seeing on activation. If you have the controller wired up but the map wire not connected or the map sensor is not sending out a good signal then it can cause it to hunt for voltage. You could have both issues.

And what are your voltage reading when the pump is running on full. The pressure switch is on top of the pump but should not make a difference because the controller is the only thing giving it power.

If you can find a surplus map sensor and let the controller power and read it I think your issue will go away.

MGordon · 10-15-2008

I initially thought my MAP could be the problem, so it was replaced two weeks ago so it really shouldnt be the source of the problem. (and all boost levels are 100% normal) I will double check that none of the wires are touching, and get a voltmeter to see what my readings are.

forcefed86 · 10-15-2008

Instead of thinking it may be this or that, why not check the map sensor with a multimeter. Should have 5 volts going in and depending on what "bar" sensor you have (you need to look it up) U can check the voltage that should be coming out (wire going to controller) at atmpspheric press. MIne was between 1.5-1.7v I believe. 3bar.

I had a similar problem when I disconnected the MAP sensor wire completly. And the controller was searching/hunting for a signal and turning the pump on and off at odd times.

Good luck!

09-09-2008	#1 (permalink)
MGordon Water Injection Newb Year: 2000 Make: Audi Model: S4 Join Date: Sep 2008 Posts: 14	My Controller woes...... A little background.. I have a 2000 Stage 3 Audi S4, located in Calgary AB... I have the 'VAST Performance' version of your kit.. Since I got the kit.. I've really had nothing but problems. I'm currently on my second controller.. and re-did the full install for the second time, and seem to be having the same problems. So for the first controller.. I used the posi lock for the MAF wire, and it didnt read accurately or get to full pump. I re-did the entire install with soldering the MAF wire, and now the green would come on accurately, but then go off at full pump, and only the yellow would stay on. (I also tested the pump and it was fine) Vast got me another controller, and after the intial install the lights work as they are supposed to.. green comes on accurately, then stays on with yellow at full. New problem? I'm not getting anything injected! The lines are dry... So.. onto today.. I re-do the install all over again for the XXth time..(Start with puling the fuse) Pump is covered in blue grime... so Im thinking its done. Nope! Works fine. (tested with water to power source) Re-did the ground, checked all the wires.. and Im hoping for the best.. Start up is normal (two blinks, then 3 fast ones) get to starting point, green works.. get to full and green light once AGAIN turns off! WTF?!?!?! Get home and check the lines.. dry once again. Please help me... Im extremely frustrated.. and ready to throw this damn thing into moving traffic. I really dont know what else to do.. My ground is bolted right to the chasis (sanded again today to make sure), Power is to an extra terminal, maf wire is soldered, pump works.. Mark

09-09-2008	#2 (permalink)
Rocket468 DevilsOwn Staff Year: 2000 Make: Pontiac Model: Grand Prix Join Date: Apr 2005 Posts: 1,124	Re: My Controller woes...... I am not actually familar with the controller being hooked up to the MAF sensor on the audi. It should be a 0-5v item. The controller is designed to be hooked up to a 2.5 bar map sensor. Might try hooking it up to the MAP sensor. When you apply 12v to the pump fluid is coming out of the nozzle? Whats covering the pump in blue grime?

09-10-2008	#3 (permalink)
MGordon Water Injection Newb Year: 2000 Make: Audi Model: S4 Join Date: Sep 2008 Posts: 14	Re: My Controller woes...... Sorry, my mistake, it was on the MAP sensor wire.. When I hooked up the pump seperately, I placed the intake hose in a bottle of water, and it pumped the water out of the bottle.. So I am fairly certain the pump works. The blue grime would be from the washer fluid, although Im not certain as where its leaking from... but its leaking from somewhere!

09-10-2008	#4 (permalink)
dvldoc DevilsOwn Staff Join Date: Apr 2005 Posts: 2,058	Re: My Controller woes...... Try this, First touch the grey wire to the green wire with the map sensor unpluged. You can use your left over posi connector to due this task. Make sure the hose is disconnected from the nozzle assembly, Let the system run for at least 10 full seconds on full. All light should come on the controller when the key is in the ignition on position. This is to clear any air out of the system. If there is air in the lines then the pump cannot clear it past the check valve and the system will stop working. Second check all your hose connections. If you have a leak this means your getting air in the system. Make sure all hose ends are cut strait with no angles on them. This can cause them to leak. Also no major bends or kinks that could be pulling the hose to the side. Also on some vehicles the ignition source wire is not up to the task of running the controller. Adding a relay will cure this little demon. __________________ Currently deployed to Ramadi 1 battalion 12th Marines Task Force MP

09-10-2008	#5 (permalink)
MGordon Water Injection Newb Year: 2000 Make: Audi Model: S4 Join Date: Sep 2008 Posts: 14	Re: My Controller woes...... And I thought it was interesting before..... So I get all the wires ready.. and first time I tap the into the green.. a fuse goes. So I replace the fuse, and turn the ignition on.. grey/green arent connected.. and I have full pump! What the shit?!? So I try a different fuse.. same thing. Even try connecting the wire while thats happening.. doesnt make a difference. So Im guessing this controller is fubar'd.. Luckily I missed the mail today so I am gonna try the old controller I was going to sen back to see if that works... On top of all of this... there is a major leak coming from the pump. My pump isnt readily accesible or in clear view so I cant see where its coming from... Im going to have wait till friday to rip the bumper off and take a look at the pump... Last edited by MGordon; 09-10-2008 at 07:55 PM.

09-20-2008	#6 (permalink)
MGordon Water Injection Newb Year: 2000 Make: Audi Model: S4 Join Date: Sep 2008 Posts: 14	Re: My Controller woes...... Following up... 1. Pump leaking.. One of the screws was loose on the top of the pump.. tightened and not leaky anymore. 2. Constant pumping.. Still doing it! Whether the MAP is hooked up or not I get full pump.. Tested with a volt meter and get the exact signal at the controller as I do the actual MAP sensor.. so would that be the controller? Or maybe part of the pump? I saw another post where the pressure switch was bent and causing the pump to be on 100%? Where can I check this? Thanks! Mark Last edited by MGordon; 09-20-2008 at 02:26 PM.

10-14-2008	#7 (permalink)
MGordon Water Injection Newb Year: 2000 Make: Audi Model: S4 Join Date: Sep 2008 Posts: 14	Re: My Controller woes...... Any help with this guys? Its been a few weeks that I have waited patiently.. I would love to get this kit running before winter.

10-14-2008	#8 (permalink)
dvldoc DevilsOwn Staff Join Date: Apr 2005 Posts: 2,058	Re: My Controller woes...... have you opened the controller to make sure you don't have a stray wire touching in there? The controller only knows voltage you need to let us know what voltage your seeing on activation. If you have the controller wired up but the map wire not connected or the map sensor is not sending out a good signal then it can cause it to hunt for voltage. You could have both issues. And what are your voltage reading when the pump is running on full. The pressure switch is on top of the pump but should not make a difference because the controller is the only thing giving it power. If you can find a surplus map sensor and let the controller power and read it I think your issue will go away. __________________ Currently deployed to Ramadi 1 battalion 12th Marines Task Force MP

10-15-2008	#9 (permalink)
MGordon Water Injection Newb Year: 2000 Make: Audi Model: S4 Join Date: Sep 2008 Posts: 14	Re: My Controller woes...... I initially thought my MAP could be the problem, so it was replaced two weeks ago so it really shouldnt be the source of the problem. (and all boost levels are 100% normal) I will double check that none of the wires are touching, and get a voltmeter to see what my readings are.

10-15-2008	#10 (permalink)
forcefed86 Alcohol Injection Join Date: Jul 2006 Posts: 49	Re: My Controller woes...... Instead of thinking it may be this or that, why not check the map sensor with a multimeter. Should have 5 volts going in and depending on what "bar" sensor you have (you need to look it up) U can check the voltage that should be coming out (wire going to controller) at atmpspheric press. MIne was between 1.5-1.7v I believe. 3bar. I had a similar problem when I disconnected the MAP sensor wire completly. And the controller was searching/hunting for a signal and turning the pump on and off at odd times. Good luck!