02/07/2026
Inefficiency and unlocking additional efficiency..
Seat Leon Cupra 2.0TSI DSG OPF version in for stage 2 custom tuning session.
We knew straight away that the hardware package would compromise the peak power potential at the top end.
Stock air box with the tiny tiny version stock rear exhaust section on this model.
(On the opf cars there's a few different factory exhaust configurations, and this unfortunately is the worst ones as you can see)
During tuning we noticed we had got the wastegate position to a level we were not happy with, we knew we were really forcing the turbo at the top end and achieving 375hp. The wastegate was at 17% opening, so lots of gas velocity and pressure speeding up the turbine wheel.
Instead of trying to force w***y waving numbers by turning up the mapping and boost with a closed wastegate, we look into where the physical inefficiency lay.
A quick back to back test was to just open up the lid of the stock air box, this test yeiled another 11+hp across the top end, with exactly the "same" boost levels BUT with the wastegate at 31% opening!
Close the air box and run again, we lost the power and the wastegate duty went back to 17%. We could see the effect with the inefficiency via the dyno induction kit vacuum sensors. With the air box closed the vacuum drawn was getting stronger and stronger with the rpm. Air box open zero vacuum drawn. We decided that the best route would be to reduce the vacuum by drilling the bottom of the air box to reduce the vacuum. We managed to reduce the vacuum drawn by over 80% allowing the wastegate to run at 30% opening, much more efficient and happier for the is38.
You can see on the logs and induction vacuum graph on the dyno the difference.
We left the settings at a efficient level at a lower bhp point, knowing that when the customer fits a r600 along with a 3" resonated cat back exhaust system, the final numbers will be at around 395-405hp without any additional tuning needed to get there.
We could have turned everything up trying to force the numbers on the day, some places would have given fake dyno numbers to keep the customer happy and make the tuning look better.
But the reality is there's hard physically inefficiency with certain hardware combinations which needs finding and common sense with the tuning approach.
Some will say, and my self "well a stock air box will do 400hp hp+" which is true on a different combined hardware package or a bigger turbo.
But at 375hp with 2500mb boost the stock air box starts to become an inefficiency as proven with this simple test.
There's no fixed power level for a stock air box or hardware as such, you could whack on a gtx3076r running 2.3bar boost at 500hp. But then fit an R600 run same 500hp power with 1.8bar or maintain 2.3bar and naturally unlock the inefficiency to see 580+hp!
Hardware is all about unlocking inefficiency when the hardware becomes an inefficiency.
The increased efficiency doesn't always show as a peak power number, as there's a lot more going on. But with good data logging you can see exactly what is going on with the hardware. The fun part of tuning is understanding what's going on , not whacking everything up to gas mark 10 with the software. Durability and reliability is more important than the final bhp.
Inefficient and efficiency are the two words I use most on a daily basis along with "getting the balance right"