100% DI Failure with Nurburgring rentals

[asnoir]

[asnoir]

Error the best is under 5200 rpm to not have the seal issue!

[asnoir]

The D4S engine use 8 injectors. At high rpm the engine become too hot and the exhaust valve must open with high frequency. The motor running upper 5200 is turning enough to refresh the combustion chamber and make the seal safety. But when you upshift upper 5200 rpm and you fall above 5200 rpm the exhaust valve as a lower open frequency and the motor overheat the seal (it can reach 150 °C) and the seal can melt. It's why Toyota says that you must upshift and waiting 0.6s to leave the combustion chamber lose is heat.

[DarkSunrise]

This would seem to weigh heavily in favor of getting an oil cooler and/or radiator upgrade if you're going to be running hard in the higher RPMs (i.e., track use). Or upgrade the seals.

[robispec]

That's why we keep our oil temps under 230 degrees f....10k track miles zero failures even supercharged!

[Porsche]

Originally Posted by robispec

That's why we keep our oil temps under 230 degrees f....10k track miles zero failures even supercharged!

Have you removed your direct injectors at any point?

If so, at what mileage, how hard was the car driven up to that point, and how did the direct injectors look?

I was reassured by Dezoris' experience, and if your injectors are fine, that would be even better still.

[track junkie]

Originally Posted by AyJay

So, are you saying you believe this IS the SA ECU reflash simply released in our region?

The previous ECU files for Subaru & Toyota.

ZA1JA00A for the JDM Manual
ZA1JA00C for the US Manual
ZA1JA00G for the EU Manual


see http://www.ecutek.com/news/newslette...r.html#reflash

[robispec]

Originally Posted by Porsche

Have you removed your direct injectors at any point?

If so, at what mileage, how hard was the car driven up to that point, and how did the direct injectors look?

I was reassured by Dezoris' experience, and if your injectors are fine, that would be even better still.

Look at the sig lol we drive the car HARD.
Yes my injectors were fouled by the stock filter coming apart. The seals were fine. This was at 8K track miles 2K street miles. 4K more track miles and just checked them again all perfect.

[Wepeel]

Originally Posted by track junkie

The previous ECU files for Subaru & Toyota.

ZA1JA00A for the JDM Manual
ZA1JA00C for the US Manual
ZA1JA00G for the EU Manual


see http://www.ecutek.com/news/newslette...r.html#reflash

Has anyone verified that the US version ZA1JA01C actually contains the updated transient ignition tables?

[thill]

Originally Posted by track junkie

The previous ECU files for Subaru & Toyota.

ZA1JA00A for the JDM Manual
ZA1JA00C for the US Manual
ZA1JA00G for the EU Manual


see http://www.ecutek.com/news/newslette...r.html#reflash

Nicely done. So it appears that any car after January 21st should have the updated software per the South African TSB/Memo.

[thill]

Wahoo! Found this, I think if you have this update you are in the clear:

This is a list of the various OEM ECU (UK/EU) MT calibrations (reflash/remap/firmware) and what changes they implement, latest at the top:


Cal Name: ZA1JA01G
Release Date: May 2013 (NOT IN UK MARKET - CONFIRMED BY TOYOTA GB JULY 2013)
Known Changes/Fixes: 1. Changes to transient spark control to resolve failing (direct) fuel injector seals caused by excessive detonation when changing gear at high engine speed (above 5200rpm).

Cal Name: ZA1JA00G
Release Date: December 2012 (tbc)
Known Changes/Fixes: 1. Updates to fix the VVT issue (rough idle, check engine light etc)

Cal Name: ZA1J700G
Release Date: Original Cal
Known Changes/Fixes: N/A


(Automatics - replace the G with I.)


If you take your car to a dealer and they intend to re-flash the car, ensure they make a note of the old calibration version and which one they've applied to verify that they have actually updated it and/or applied the right one to fix the issue. I've heard of cases where dealers have actually flashed a car with an older cal or just re-applied the same one. Seems a bit of a knowledge/education/familiarity problem.


Edited by Stu - 01 Aug 2013 at 3:17pm

http://www.gt86ownersclub.co.uk/foru...topic3531.html

Next time my car is in for service I will be verifying my calibration file, but my car had a March 2013 build date so I should be good.

[Porsche]

Originally Posted by robispec

Look at the sig lol we drive the car HARD.
Yes my injectors were fouled by the stock filter coming apart. The seals were fine. This was at 8K track miles 2K street miles. 4K more track miles and just checked them again all perfect.

Thanks.

Do you have a different tune, a modified ignition mapping, that might contribute to your engine durability where other engines have melted down?

[Wepeel]

Hmm. Looks like the guys in SA who have had the 00 -> 01 update have reported some better mid range bump as well (pulling out of the dip a few hundred RPM sooner):

Subective claims and dynos:
http://www.ft86club.com/forums/showt...99#post1090499

I'm assuming since I have a build date of May 2013 I should be good to go.

[robispec]

Originally Posted by Porsche

Thanks.

Do you have a different tune, a modified ignition mapping, that might contribute to your engine durability where other engines have melted down?

Yes we broke the car in then had it tuned for race gas/E85
We have always run 5w30 oil and have a HUGE radiator/oil cooler combo.
I think all these problems stem from too hot oil.....as the hotter the heads get the higher your chances of detonation happening, and detonation is what kills the seals.