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Old 04-23-2013, 10:01 PM   #1
neo277
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FP TDO5 18G! DCCD 07 6mt

Have a Nice Day? 04 wrx shuts off during hard cornering

Hello Nasioc.

I have a 04 wrx with 109,000 on her so far.

Hoping to get some help with this issue that has me stumped for some time now. ( sorry for the long read but wanted to give all the details to help diagnose my issue)

To start off i have been having this issue that occurred on 4 or 5 occasions over the last year and a half, it happens While very hard cornering (making a hard right turn, 10mph 90deg turn) as i am going about 40~mph's. It happens right after i hit the apex of the turn and accelerate, then she will shut off almost like she ran out of fuel ( its always happened when i have about 3 to 5 gallons in her, so lets say roughly about a 1/4 tank or under of fuel.

After this happend the 1st time i guessed it was my walbro 255 crapping out, so i replaced it with the DW300 pump. than it happend again so i thought maybe my fuel pump relay, replaced that and all was good for a while until today lol, on my way home on the same back roads i entered the same corner and was going about 30-40mph's and she did it again

So after pushing her to a safe spot off of the road and letting her sit for 20 or so minutes i started her back up and she fired up with no issues, no DTC's and all was well.

At this point i have no clue what to do. I have read that some wrx's have this issue when under a 1/4 tank of fuel but i have never had this issue before and have driven her just as hard.

Here's a mod list just as a fyi.

Car was e-tuned by the one and only Ron Watson ( Phatron) of Phatbotti tuning, and currently running 93+meth (50/50 mixed by me)

Engine:
- Forced Performance TD05 18G 7cm2 turbo ( ported & polished )
- NGK Iridium. 1 step colder plugs
- Killer B oil Pan, Pickup Tube, Oil Shroud
- Hallman pro Manuel boost controller
- Grimmspeed 3 port ebcs
- Deatschwerks 750cc Injectors
- DW 300 fuel pump
- FMIC turbo xs
- Perrin catch can
- Perrin Turbo Inlet
- Forge recirculating bpv
- Fluidyne radiator
- K&N Intake cone.
- Cobb light weight Crank pulley
- Invidia Bellmouth 3” catless downpipe w/2 o2 bungs
- Perrin EL Headers
- Perrin 3” twin tip cat back exhaust
- Grimmspeed coated up-pipe w/ tial-mvs 38mm v-band external wg w/dump tube
- Gates racing timing belt
- IPR Aluminum timing belt guide
- 2008 sti 11mm oil pump
- Snow performance stg 3 meth injection with safe injection module, cm7 coolingmist nozzle.


Drive train:
- 2007 STI 6mt - 3.636 / 2.235 / 1.521 / 1.137 / 0.971 / 0.756 / 3.900FD
- Kartboy shifter bushing
- Aluminum pitch mount
- Gruppe N motor/transmission mounts
- Gruppe N crossmember bushings
- ACT SB3-HDSS Clutch kit (for 5spd)
- ACT Streetlite flywheel – 13.9lbs (for 5spd)
- 3inch DriveShaftShop Aluminum Drive shaft ( for 6mt)

Brakes:

- 2004 STI Brembo F/R calipers that i stripped down and painted red with white brembo stickers.
- Front DBA Rotors
- Rear DBA2657 Slotted Rotor
- Hawk hps f/r pads
- Techna fit SS F/R steel braided lines

Suspension:
- Front/rear strut tower bar
- BC BR 32 way adjustable coil-over suspension with rear adjustable extenders.
- MSI cnc machined rear adjustable lateral links
- SPT Front Aluminum control arms
- Whiteline rear toe lock bolts
- GT Spec pillowball rear trailing arms
- Whiteline HD Front/Rear Endlinks
- Energy suspension Rear trailing arm bushings
- Kartboy rear diff mount bushing
- Kartboy rear(front) diff support bushings
- Kartboy rear sub frame lock bolts

Wheels/Tires:

- Enkie RPF1 17x8
- Hankook RS3 245/40/17

Electronic:

- Dccdpro universal center diff controller
- Innovate LC-1 DB Blue wideband
- Autometer CF series Boost Gauge
- Autometer CF series Volts Gauge
- Prosport premium oil pressure gauge
- Prosport premium egt gauge

Interior:

- Sabelt Titan race seat (driver)
- NRG harness bar
- NRG 4 point harness's

here's a pic for your viewing pleasure.



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Last edited by neo277; 04-24-2013 at 11:41 PM.
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Old 04-23-2013, 10:03 PM   #2
Jacobs11
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May be a stupid question but is your oil low?
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Old 04-23-2013, 10:14 PM   #3
neo277
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No sir, i check my oil before i drive the car, meaning religiously. : )
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Old 04-23-2013, 10:16 PM   #4
Concillian
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I think this is fairly common under 1/4 tank. I know I've experienced it.

I thought I broke something. Car died and wouldn't restart. I thought the FP was a problem. Started checking fuses and relays, connectors, etc... and couldn't find anything.

It happened right next to work, so I went to work and worked for a bit, came out with a multimeter to test voltages and it fired right up. DW300 and ID1000s at ~80% duty cycle at peak.

Dunno, but it must be some kind of fuel starvation. It happened on a right turn, which would be when fuel would slosh away from the pump. I doubt it will happen often on lefts.
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Old 04-23-2013, 10:20 PM   #5
neo277
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Hey Concillian, its funny that you say it wouldn't happen on left turns, as it never happened to me on a hard left, ( taking the same corner but heading in the other direction) its only happened to me on the hard rights and about 1/4~ tank of fuel.

Cant imagine that its that simple but who knows huh.
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Old 04-23-2013, 10:38 PM   #6
Whoracle
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This happened to me recently getting on the freeway 2 days after getting my car back after 4 months of work (body work followed by an ej207 swap). I was getting on the freeway, soon as hit the apex of the corner I got on it a bit (about 30mph to 70mph pull to merge) and as soon as i hit 70 the car shut off. I had slightly under 1/4 tank, with a DW300 fuel pump. Cobb AP showed fuel pump controller error (but it was a JDM ecu so not sure how accurate it is) and it wouldnt start up again.. Had it towed to the shop and it fired right up once we got there >.<. Hasn't done it since, so I think it is probably glitch in the matrix.
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Old 04-23-2013, 10:48 PM   #7
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Fuel pump is on the right side, so I imagine when making a hard right with low fuel it is likely you aren't getting enough fuel. Just a thought.
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Old 04-23-2013, 10:52 PM   #8
neo277
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Awesome Whoreacle, "glitch in the matrix" hahaha

I wonder if its due to the fuel tank design or something but out of all the wrx's out there I haven't heard many people having this issue. Very weird and hate that I cannot pinpoint the issue.
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Old 04-23-2013, 10:54 PM   #9
neo277
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I thought the same thing "jesterduck" but is a 1/4~ of a tank considered to be low fuel? Might be a dumb question lol
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Old 04-23-2013, 11:12 PM   #10
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Quote:
Originally Posted by neo277 View Post
I thought the same thing "jesterduck" but is a 1/4~ of a tank considered to be low fuel? Might be a dumb question lol
Quote about the Rallitek Fuel Tank Baffle;

"When sweeping through high speed corners, your Subaru's fuel tends to slosh to one side, causing your fuel pickup to starve. This alloy surge tank is baffled to prevent fuel starvation/lean out situations when pushing your Subaru to the limit."

No guarantee it is your case, just makes sense to me.
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Old 04-23-2013, 11:32 PM   #11
neo277
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Thanks all for the replies, it does make sense to me and I understand the position of the pump can cause an issue with fuel starvasion during hard cornering. I guess ill have to make sure I'm above 1/2 a tank when racing and taking hard corners for now until I invest in an upgrade.

Thanks again

Z
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Old 04-23-2013, 11:36 PM   #12
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my 03 does this too ...i found a post where you use a big R/C plane Fuel tank and mod it and add a hose from your return jet and put the pick up sock in the modded plastic tank ...and put the hose from the return jet into the R/c tank.do a serch and you will find it .there are pics and every thing ..cost about $10.00 to fix this .it should be a recall as far as im concerned ....having a sports/rally car with fuel pick up proplems on hard right turns come on subaru
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Old 04-23-2013, 11:43 PM   #13
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found it google "shanes impreza fule solsh mod " great fix .
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Old 04-23-2013, 11:48 PM   #14
neo277
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Quote:
Originally Posted by wrx1392 View Post
found it google "shanes impreza fule solsh mod " great fix .

Thank you sir, funny you just posted and I stumbled onto it. I agree how this is such a stupid problem and one would think Subaru would correct this.

O well, ill have to do this mod and test it out and ill post up the results

Thanks again

Z
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Old 04-23-2013, 11:52 PM   #15
wrx1392
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yeah i need to do mine too .im into R/C jets so im sure i have a old tanks laying around ...i do all electric powered now but i used to run the messy gassers back in the day. this happen a lot to my car and i bet it helped trash my pistons ring lands,my poor wife was driving the car when it siezed up on her. funny i never noticed this when the car was new.good luck keep us posted .
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Old 04-23-2013, 11:57 PM   #16
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Quote:
Originally Posted by wrx1392 View Post
found it google "shanes impreza fule solsh mod " great fix .
I like that fix. Much cheaper and easier than buying or making an inline surge tank.

OP, glad to see you have already addressed the oil pickup issues of the EJ205 with the KillerBee products.
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Old 04-23-2013, 11:59 PM   #17
neo277
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Quote:
Originally Posted by wrx1392 View Post
yeah i need to do mine too .im into R/C jets so im sure i have a old tanks laying around ...i do all electric powered now but i used to run the messy gassers back in the day. this happen a lot to my car and i bet it helped trash my pistons ring lands,my poor wife was driving the car when it siezed up on her. funny i never noticed this when the car was new.good luck keep us posted .
Will do and thanks again, it never happened to me when mine was stock either, I guess all of the upgraded suspension parts really pushed the fuel sloshing to the max. Ill be getting on this ASAP as I have a race in two weeks, ill post up pics and testing results after i install it.

Good nite

Z
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Old 04-24-2013, 03:20 PM   #18
Concillian
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Suspension difference between stock and springs + struts + bushings + tires is HUGE.

Don't forget that these things came with 205/55 RE92 all seasons stock. Just tires is enormous. Back in the day, people worried about dealers denying warranty issues just because they had new wheels and summer Z / W / Y rated tires.

Now WRXs come with 17x8 and summer W rated tires... oh how the times have changed.
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Old 04-24-2013, 04:07 PM   #19
neo277
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Quote:
Originally Posted by Concillian View Post
Suspension difference between stock and springs + struts + bushings + tires is HUGE.

Don't forget that these things came with 205/55 RE92 all seasons stock. Just tires is enormous. Back in the day, people worried about dealers denying warranty issues just because they had new wheels and summer Z / W / Y rated tires.

Now WRXs come with 17x8 and summer W rated tires... oh how the times have changed.
So true, I guess all of the suspension upgrades along with running 245 40 17 hankook rs3 is really tossing the fuel around when I'm below half a tank.

I ordered a 32oz dubro plastic nitro fuel tank and going to do the Shane's surge tank mod. Ill post up pics and data after testing it out. I'm sure it's going to take care of this little issue. Can't beat a $13 fix. Im glad i didnt have to shell out the dime for a trunk mounted surge tank setup at this point.
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Old 04-24-2013, 05:04 PM   #20
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The way or tank works, the pickup is on the right with the axle hump in the middle, leaving several gallons "inaccessible". Subaru plums the return line from the engine first to the left side of the tank where they have a secondary pickup which is a jet pump (venturi), which moves that fuel to the main pickup. So I was getting fuel starve up to nearly half a tank until I replaced the tired stock fuel pump.

The ability to move fuel from the left side is directly related to the excesses volume of fuel you're pump can move after the injectors take their fill. The slosh mod can help but for sustained track corners you may run or of excess fuel if the secondary pickup never replenishes the right side.

You could have a leak, maybe even in tank reducing pump volume, are you running the correct voltage, maybe your secondary pickup is clogged or you return line is loose or clogged.
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Old 04-24-2013, 05:06 PM   #21
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Slosh mod = bandaid, id guess there is an issue somewhere. The secondary pickup is accessible under the back seat on the other side.
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Old 04-24-2013, 06:40 PM   #22
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Quote:
Originally Posted by penderperson View Post
Slosh mod = bandaid, id guess there is an issue somewhere.
Well, the correct solution is a surge tank, but who wants to use trunk space for a second fuel tank?.. Not to mention how much more it costs.

There's something to be said for simple cheap solutions. Call it a band-aid if you will, but it's essentially what Subaru has done for the 08+ pump hangar.
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Old 04-24-2013, 09:51 PM   #23
neo277
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Quote:
Originally Posted by penderperson View Post
The way or tank works, the pickup is on the right with the axle hump in the middle, leaving several gallons "inaccessible". Subaru plums the return line from the engine first to the left side of the tank where they have a secondary pickup which is a jet pump (venturi), which moves that fuel to the main pickup. So I was getting fuel starve up to nearly half a tank until I replaced the tired stock fuel pump.

The ability to move fuel from the left side is directly related to the excesses volume of fuel you're pump can move after the injectors take their fill. The slosh mod can help but for sustained track corners you may run or of excess fuel if the secondary pickup never replenishes the right side.

You could have a leak, maybe even in tank reducing pump volume, are you running the correct voltage, maybe your secondary pickup is clogged or you return line is loose or clogged.
I'm still on stock wiring and upgraded my main pump, i Originally had the walbro255 until this issue arose so i changed it out for a dw300. I never knew that the 04's had a secondary pump as I thought that was on older models.

Thanks for the feedback

Z

I'll check the secondary pump/pickup and the return line going to it to see if there is an issue.

Last edited by neo277; 04-24-2013 at 10:00 PM.
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Old 04-24-2013, 10:29 PM   #24
neo277
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Quote:
Originally Posted by miracle_whip4130 View Post
I like that fix. Much cheaper and easier than buying or making an inline surge tank.

OP, glad to see you have already addressed the oil pickup issues of the EJ205 with the KillerBee products.
I agree about the inline surge tank, I've looked into it over the many years that I've owned this car and it's a pretty expensive option but I might end up doing it if I can't solve this issue after Shane's slosh mod and checking the return lines along with the secondary jet pump.

Thanks, I had to switch up oil pans since I switched to EL headers and decided to go with killer B's full setup. I have to say they are quality products.

Last edited by neo277; 04-24-2013 at 10:50 PM.
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Old 04-24-2013, 11:11 PM   #25
amroof
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You can always install an sti fuel pump assembly minus the pump as you have an upgraded one. The sti has a small slosh tank built into the pump assembly were the wrx or any other turbo model doesnt. I have this same issue at 1/4 tank or lower in my 207 swapped fxt with an aeromotive 340. I have tried to lower it further into the tank and that helped a little, But a surge tank would work awesome.

I have a sti assembly sitting in my box at work and just havent had time to try it out. If I get a chance to install it I will let you know if it works out.
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