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Old 02-19-2010, 02:16 PM   #1
desmo750
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Default 92 Legacy turbo intercooler problems

Ok, I have a 92 legacy ss (ej22t). I have a td05 16g turbo, manual boost controller, fuel cut defender, and it had an 02 wrx tmic which worked great except for the fact that it was smashed in there and didn't fit well. Never had a problem with the car when it was installed. I decided to buy a new 06 wrx intercooler since they fit so much better. Had problems with what I figured to be a boost leak somewhere yesterday and got it resolved and the thing ran great. Drove it home 30 miles ran like a speed demon. This morning I'm on my way to work and it's doing the same thing: boosts up to about 5 lbs then falls on it's face, almost dies, then runs ok after a second if I don't give it too much throttle. Get to work, double check everything, give all hose clamps a double tightening, am dumb founded, go drive it runs great. On the way back, same thing. I cannot find a boost leak but there must be one since it's running like this . Anyone run into this problem? Like I said, when I had the 02 intercooler I never had a problem. Everything with this new one fits tight, hose clamps tightened down, and I cannot find the problem.
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Old 02-19-2010, 02:45 PM   #2
94EJ22TImpreza
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I have the same set up in my 94 Impreza and the same problem.

nothing so far has worked i would love to see some new suggestions.

hope you fix it...Good luck!
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Old 02-19-2010, 04:11 PM   #3
curt
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Quote:
Originally Posted by 94EJ22TImpreza View Post
I have the same set up in my 94 Impreza and the same problem.

nothing so far has worked i would love to see some new suggestions.

hope you fix it...Good luck!

if you're in snohomish can i take a look at how the 06 wrx intercooler fits on the older motors? im in lake stevens on my days off, in shoreline for school. i'd like to take a look at your setup.
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Old 02-19-2010, 04:57 PM   #4
desmo750
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Alright just checked the codes. Ecu has 3:
24: By pass air control valve
31:Throttle postion sensor
22:Knock sensor

Strange that the car always ran fine until I did the intercooler swap then these three codes turn up
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Old 02-19-2010, 09:27 PM   #5
klin7757
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clear the codes and see which ones reappear. my guess, knock sensor comes back and a new sensor is in order.
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Old 02-20-2010, 04:36 AM   #6
94EJ22TImpreza
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Quote:
Originally Posted by curt View Post
if you're in snohomish can i take a look at how the 06 wrx intercooler fits on the older motors? im in lake stevens on my days off, in shoreline for school. i'd like to take a look at your setup.

Sure pm me a day you have off and we can set up a time to meet.
im in Lake Stevens a lot so just about any day would work.
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Old 02-20-2010, 04:43 PM   #7
desmo750
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Quote:
Originally Posted by klin7757 View Post
clear the codes and see which ones reappear. my guess, knock sensor comes back and a new sensor is in order.
Cleared codes, they all came back
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Old 02-20-2010, 07:41 PM   #8
MikeyMeyagi
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check the knock sensor wiring, may be shorted
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Old 02-20-2010, 08:34 PM   #9
69subaru360
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Thats a lot of codes for just a bad knock sensor. Maybe you broke or left off a ground wire.
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Old 02-21-2010, 04:07 PM   #10
desmo750
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Quote:
Originally Posted by MikeyMeyagi View Post
check the knock sensor wiring, may be shorted
I'll check that tomorrow, anything else I should look for?

Last edited by desmo750; 02-21-2010 at 05:59 PM.
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Old 02-22-2010, 07:59 AM   #11
ncarn8
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its not happy that the afm and the iacv arent reporting the same information maybe. I would still be sniffing around for air leaks that may only happen when positive pressure opens them like small gaps in the hoses etc. . At idle doesnt mean squat really. Also remove and clean the iacv, replace the knock sensor and reset the throttle position sensor to where the marks are on it. should be some white paint. after all that it should be better

Last edited by ncarn8; 02-22-2010 at 08:01 AM. Reason: read post wrong
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Old 02-23-2010, 02:20 PM   #12
desmo750
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Found the problem The wiring in the throttle position sensor plug was exposed in a few places and touching. Looks like someone had tried to repair it before and didn't do a very good job. Insulated them and car runs great! It was right in front of me the whole time but since it happened when I replaced the intercooler I thought I had a major boost leak.
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