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Old 07-22-2009, 01:51 AM   #1
RS2580401
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Default Turbo Kit Issues

I recently turbo'd my Ej22E. It runs great under 4000 rpm but once I hit ~4k, the motor shudders and I lose power temporarily. It then gets to ~4300, and loses power and so on. The car was turbo'd with a TD-04 on custom up and down pipes. The UP is catless and the DP has 2 cats. I have started trouble shooting with not much luck. I installed a Rising Rate Fuel Pressure Regulator with a 12:1 plate inside thinking I was running too lean and the car was getting knock. That did nothing. I had a Voltage Clamp placed on the Map sensor so that my stock Map sensor would not see boost and freak out. That did not work. I also had a wideband O2 sensor placed in the down pipe so that we could really see what was going on. I am actually getting enough fuel. The AFR under boost was 11.4:1. I am out of ideas on how to fix this studdering under load. Could it have something to do with the spark plugs? As I changed out my valve cover gaskets a month ago, I noticed that a spark plug boot terminal came out. I placed it back in the boot and attached it to the spark plug. It seemed to be fixed but maybe that is causing the issue. The spark plugs have ~25k miles on them. Do I need to adjust the gap?
Any and all ideas will be much appreciated. Thanks

Mark
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Old 07-22-2009, 02:21 AM   #2
PhilSine
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I had the exact same problem. I never figured out why. What's happening is the ECU is cutting fuel for just a beat. I was able to tune around it using an E-Manage Ultimate but it still bothered me not knowing why it had been doing that.

It was clear in the data logs what was happening. If I gradually raised the RPM's it wouldn't do it but under hard acceleration it would be there. I have a feeling that its some kind of switch-over programmed into the ECU that under normal (NA) acceleration and fuel delivery wouldn't be noticed but under the much faster and heavier fuel load needed for boost it becomes obvious.

Just my hypothesis. I say live with it or invest in better EM that allows you to tune out the hiccup.
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Old 07-22-2009, 02:42 AM   #3
RS2580401
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Hmm good to know I am not the only one with these issues.
There is a guy on RS25 I know that has an EJ22 with a Map sensor setup. He did all the things I did and does not get this studder. It is weird. I wonder why my car is reacting differently.
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Old 07-22-2009, 10:40 AM   #4
RS2580401
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Bump.
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Old 07-22-2009, 05:37 PM   #5
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25k on the plugs? Time for new ones - go one step colder while you're at it since you're turbocharged.

You could have a vaccum leak. May not even be in the vaccum hoses, could be in one of the vaccum devices, like the MAP sensor or purge control solenoid that doesn't know what to do with positive pressure.
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Old 07-22-2009, 09:42 PM   #6
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Come to think of it, mine did that too. I run a MAF, so I doubt it has anything to do with your MAF. I was running stock legacy turbo plugs, and it only happened when it was cold. My only idea was my fuel pump wasn't good enough, but since I tuned around it, I know that to not be the case.
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Old 07-22-2009, 10:50 PM   #7
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You have no EM, correct?

How much boost?

12-1 rrfpr means that at 5psi you are running about 106 psi give or take.... WAY too much.....
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Old 07-23-2009, 01:04 AM   #8
RS2580401
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I am only running 3.5 lbs of boost at the moment.
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Old 07-23-2009, 01:12 AM   #9
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i have a crazy problem , my car was not turbo i put in a haltech ECU but when we tune the car it just wont go over 4.800 Rpm its like it running out of spark or gas , and i have STI coils and 255 fuel pump check everything cant find the problem .... i try with another ECU same model same problem WTF !!!

any sugestions ??
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Old 07-23-2009, 01:24 AM   #10
reddevil
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Quote:
Originally Posted by RS2580401 View Post
I am only running 3.5 lbs of boost at the moment.
Probably still to0 big maybe?..

You are running stock 270cc injectors

At 3.5 psi you are now running equivilent of 370, about a 35% gain,

http://www.witchhunter.com/injectorcalc1.php4


Another thing is you could be maxing the MAF signal. When is it hitting 5 volts?
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Old 07-23-2009, 03:49 AM   #11
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I have a MAP sensor that has a voltage clamp.
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Old 07-23-2009, 04:37 PM   #12
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Quote:
Originally Posted by reddevil View Post
Probably still to0 big maybe?..

You are running stock 270cc injectors
Im running 7psi on stock injectors with no EM. Im not maxing out the MAF signal either.
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Old 07-24-2009, 01:07 AM   #13
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sounds like you're running really rich. 4k rpm is when the ecu usually switches to open loop fueling. And you're putting 10% more air and +-35% more fuel. reading AFR's is really tricky when you have misfires because they show up as lean spikes that counteract the rich readings. But, it could also be someting else.
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Old 07-24-2009, 09:08 AM   #14
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Quote:
Originally Posted by Abest10 View Post
Im running 7psi on stock injectors with no EM. Im not maxing out the MAF signal either.
+1 about not maxing out the MAF sensor. Try removing the RRFPR and see what happens. Your boost level of 3.5 psi is low and there is NO way you will hurt anything.
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Old 07-24-2009, 12:53 PM   #15
RS2580401
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Quote:
Originally Posted by 2milehi View Post
+1 about not maxing out the MAF sensor. Try removing the RRFPR and see what happens. Your boost level of 3.5 psi is low and there is NO way you will hurt anything.
I had the RRFPR off before and it had the same symptoms.
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Old 07-27-2009, 02:05 AM   #16
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Just put in the new plugs today. The knuckle heads told me they were gapped to .03 but when I measured them at home, they were actually at .035. The plugs that were in my car were gapped at .047. This made a HUGE difference. The car runs very well now. There is still a slight studder but it is irregular unlike before. I had a plug wire terminal come off while changing the valve cover gaskets and my guess is that the connection is not that great. New plug wires have been ordered.
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Old 07-27-2009, 09:22 PM   #17
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Glad you got it working again and it was a simple fix.
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Old 07-27-2009, 11:06 PM   #18
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"+1 about not maxing out the MAF sensor. Try removing the RRFPR and see what happens. Your boost level of 3.5 psi is low and there is NO way you will hurt anything."

is that reallytrue. It just dosent seem safe to me, wouldnt it be runing lean

OP-can i get some details about ur build. Im doing on kinda similar its just on a ej25

Thnx
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Old 07-28-2009, 10:19 PM   #19
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i have a 2.2 with aftermarket turbo kit installed and i'm only making 3lbs of boost at the moment. i have 2 extra injectors right before the TB that i can control with FMU. i also feel my clutch slipping a bit when making boost. any pointers besides the clutch upgrade?
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Old 08-04-2009, 03:57 PM   #20
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Quote:
Originally Posted by turbo01gc8 View Post
i have a 2.2 with aftermarket turbo kit installed and i'm only making 3lbs of boost at the moment. i have 2 extra injectors right before the TB that i can control with FMU. i also feel my clutch slipping a bit when making boost. any pointers besides the clutch upgrade?
Are you doing anything to control timing?
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Old 08-10-2009, 12:29 AM   #21
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So this weekend I tightened the spark plug gap to a .025. That worked for about an hour before it started with the same symptoms again. It is really only noticeable in second gear. It feels like a parachute deployed from the back of my car temporarily. AFR readings are right where they need to be too. Is it safe to go with a smaller gap? I would think not.
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Old 08-10-2009, 11:23 AM   #22
RS2580401
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I am going to put in new plugs and check the voltage clamp tonight.
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Old 10-02-2009, 01:07 AM   #23
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nothing to control timing. just got done cutting and rethreading the wastegate actuator rod and now making 7 psi but not very reliable. boost guage flutters when making boost over 2psi
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Old 10-02-2009, 01:09 AM   #24
RS2580401
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Quote:
Originally Posted by turbo01gc8 View Post
nothing to control timing. just got done cutting and rethreading the wastegate actuator rod and now making 7 psi but not very reliable. boost guage flutters when making boost over 2psi
Do you have a fuel pressure regulator in your fuel lines? Are you getting fuel cut?
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Old 10-02-2009, 01:13 AM   #25
turbo01gc8
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have fuel pressure reg. doesn't seem to have fuel cut cause i don't get too close to the redline @ 6250. can only control 2 injectors out of 6. can up the m/s across boost and rpm so not sure. on a hard run sometimes says i hit 7psi @5700 but once in a while?not constant
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