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Old 03-31-2009, 03:49 AM   #1
thepigsti
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Join Date: Dec 2007
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Default Another STi won't start after intake mani removal

Sorry create my own post for this but I am running out of time before my tuning appointment.

This past weekend I installed a bunch of stuff (see below) and now the car won't stay running. It is turning over then revs up for a second and then dies. Subsequent attempts to start will rev up for a second then die. If I give it a little gas it will rev and run a bit rough perhaps, but sputters and dies quickly if I don't. This leads me to believe it is at least getting fuel and spark. Car ran fine previously, and the following are new as of this weekend:

APS turbo inlet
Blouch Dom 3
DW 740 injectors
Prodrive BCS
Grimspeed TGV deletes and phenolic spacers
Perrin EL header
Grimspeed up
Perrin FMIC
KSTech 73mm big MAF CAI

Checked my grounds twice; no luck. Reversed the fuel lines at the stock regulator and the pump got louder and it still didn't start. No codes either. Made sure the MAF is not reversed (wires toward front of car), all the coilpacks are in their right spots, checked all electrical connectors and vacuum lines for proper placement. No fuel leaks that I can see or smell, the area around all 4 injectors is bone dry. I checked all the post MAF couplers but I guess I will try that again.

I have a tuning appointment tomorrow, so I will be up all night until this is working. Any help is much appreciated, I am going to keep digging. By the way the custom map I am running is from Surgeline, not some brotune cooked up on a Speak-and-Spell. Thank you for looking.


Full mod list
Cobb AP V2 with custom safe map (for all mods below)
DW 740cc injectors
Walboro 255lph fuel pump
NGK one step colder plugs
Prodrive 3 port BCS
KStech 73mm CAI
APS turbo inlet
Blouch Dom 3 turbo (2.4" inlet)
Perrin FMIC
APS 50/50 BPV
Grimspeed TGV deletes and Phelolic spacers
Perrin EL header
Grimmspeed up
iNvidia V3 DP
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Last edited by thepigsti; 03-31-2009 at 09:29 AM.
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Old 03-31-2009, 04:35 AM   #2
Nuke209
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2003 WRX
NF Performance

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were u tuned for that 73mm cai?
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Old 03-31-2009, 08:01 AM   #3
thepigsti
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Yes, I was told the map accounted for the 73mm CAI as well as the DW740 injectors.
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Old 03-31-2009, 08:10 AM   #4
WeldingHank
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PSM

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make sure your fuel feed and return lines aren't reversed.
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Old 03-31-2009, 08:59 AM   #5
thepigsti
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Yea I tried that after reading another thread, the pump priming noise got a lot louder and it wouldn't start either. I have the relocated stock FPR that matches the APS inlet install instructions exactly. Thanks though.
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Old 03-31-2009, 09:04 AM   #6
STIBungy
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Check for any leaks in the intake manifold. You may have forgotten to tighten it down or left a vaccuum line undone. Make sure all your sensors and injectors are plugged in. Are there any CELs?
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Old 03-31-2009, 09:17 AM   #7
thepigsti
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No codes unfortunately, I am checking all vacuum lines and sensors yet again but only because I am out of other things to check that I know about.

It does the same thing no matter what I do, turn the key and it fires revs up to about 3k and dies. Trying to start after that without re-priming the fuel pump it will rev up to maybe 1k before dying. I can keep it running if I give it a little gas, but it sputters out at lower RPM; seems be pretty rough however.

Last edited by thepigsti; 03-31-2009 at 09:24 AM.
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Old 03-31-2009, 09:39 AM   #8
gabedude
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Try unplugging the MAF, then starting it. That will tell you if the issue is around the manifold and not some other part that may be leaking (like a turbo hose).
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Old 03-31-2009, 09:58 AM   #9
thepigsti
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Finally a change! I unplugged the MAF connector and it revs up to around 4k and holds steady. What does this mean? I am scrubbing through the manual as we speak.
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Old 03-31-2009, 10:52 AM   #10
gabedude
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There is some leak before the TB or the tune is off. Just contact your tuner and tell him what is going on.
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Old 03-31-2009, 01:41 PM   #11
thepigsti
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I just rigged up something so I could attach the MAF housing directly to the TB and eliminate the turbo inlet, turbo and all the intercooler piping. Same exact behavior. The only other places for leaks (to my knowledge) is the TB, manifold to TGV and TGV to head.

I guess I will start tearing everything apart again.
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Old 04-01-2009, 02:05 AM   #12
stock06sti
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i had this same problem after doing tgv deletes and injectors it turns out we stretched out and tore the o ring that sealed to fuel rail to the tgv NOT on the injector itself i had to replace it and it fixed it
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Old 04-01-2009, 03:06 AM   #13
methaddict
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Full Race TS, BW 8374 EFR

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Check all around the phenolic spacer, tgv's, and gaskets to make sure they are seated flat. If the hard inlet isn't orientated just so it might have obstructed you from seating the manifold to the tgv's or the tgv's to the head. If there's the slightest gap, you'll have a huge vacum leak. It's a tight fit with factory fuel lines and bov recirculating hose and vacum lines. Make sure your vacum lines or fuel lines aren't pinched. Be very careful of the routing of the fuel lines. Some of my stock fuel lines actually got cut from being to close to sharp edges from hard pipe brackets that had to be cut.
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Old 04-01-2009, 04:03 AM   #14
drmichael
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SMG

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I've had the same problem a while back, and it turned out to be a bad fuel pump. Hope you get it running soon.
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Old 10-29-2012, 04:38 PM   #15
Quiksmith
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What was the verdict on this issue?
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Old 10-29-2012, 10:19 PM   #16
UK-Wagon
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Check that you plugged in the crank and cam sensors!
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