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Old 05-04-2005, 12:48 AM   #1
Justin962
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Member#: 43253
Join Date: Sep 2003
Location: DFW
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2004 WRX Sedan
PSM

Default Help me narrow down my problem please - Air leak or Turbo problem?

I bought a td05-20g turbo from Deadbolt last April & just got around to installing it due to buying the other mods. While installing, I ran into a problem - the housing was too thick and it was rubbing against my TGV sensor. After a few emails, I was told I could sand down the turbo so that it would clear the sensor. To my surprise, there was a threaded hole where I was sanding about a 1/4" down. I returned the turbo and had them recoat it & remove all the shavings inside. Once I got it back, I put everything on and it started up fine. Here are my mods.

20g
fmic
modded stock injectors
tbe & up
utec
fuel pump


I went to my local tuning shop, excited that my year long project was soon to be completed. To my disbelief, there was a problem. When running it on the dyno at 12psi, the car would begin to dump fuel when it began to see any signs of boost. Even when he tried to scale the injectors higher and lower than the rated flow, it did the same thing. So we figured there was a air leak causing the car to dump fuel to match the abundance of air coming in. We swapped the intake & bov and came up with no luck. After trying to figure it out for 5 hours, I was sent home to see if there was a leak in the intercooler. So today, I put the stock top mount on & came up with the same problem. My car boggs at 3k rpm, then will rev up to 5k, and then bogg after that. Keep in mind that I can hardly push the pedal down, or else it will do the same thing. I have to gradually push the pedal down for the car to accelerate. I can feel the car wanting to boost right around 3k rpm & trying to work, but it just isn't. Steve at FIS said the Utec was working fine and he tried many different maps & settings. The gaskets on the dp & up should be just fine as well, but I will double check if I go the route of taking my turbo off.

So my question is before I go rip out my turbo and put the stock one back in, does this sound like a turbo problem, or could the modded injectors be at fault? Steve said he felt the injectors were fine, but I've been skeptical about these modded ones, even though they were infact flow tested at 760 I believe. Am I on the right track, or is there something else that can be at fault?

Thanks for any help,
Justin

Update on 3rd post.
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Last edited by Justin962; 05-28-2005 at 07:11 PM.
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Old 05-04-2005, 11:56 AM   #2
phantomsr
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Best way to find a leak anywhere in the intake is to take off the airbox and toss a plug in the inlet or MAF hose. Grab a compressor and pump air into the intake, I use the BPV line. If there is a leak anywhere from the heads to the intake you can hear it. Much easier than trying to hear a small leak over the engine noise. Just make sure you watch how much air you put on and stay under 20 PSI or so.
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Old 05-04-2005, 10:40 PM   #3
Absubtle
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That is a very good idea PhantomSR. I was just gonna mention putting a vacuum gauge on the manifold and just monitor it. When the car is acting up.
Absubtle
PA
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Old 05-28-2005, 07:03 PM   #4
Justin962
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Thanks phantomsr, I tried your idea but did not hear a leak. I went ahead and threw the stock turbo on and experienced the same problems. I then decided to plug my up pipe since the egt probe was broken off & did the resistor mod. The same results came up. So finally, I resorted to removing my Utec and basically leaving my car stock + tbe, injectors, fmic, and fuel pump. I drove down the road and it seemed like my car was fixed! I could put the pedal to the floor & redline each gear with zero problems, well for 2 miles at least... The problems I mentioned in my first post then came back from the dead and now leads me to believe it is one of two things... injectors or fuel pump. I bought both used, but I am leaning towards the modded stock injectors (even though they were flow tested, which was almost 2 years ago) Anyone have any suggestions? I am really contemplating about going back to stock just so I can have a car I can drive. Help me get out of my jeep!!

Thanks-
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Old 05-28-2005, 08:06 PM   #5
hondaeater69
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I'm assuming you've tried this but I"ll throw it out there, Hard ECU reset? (neg bat terminal pushing on brake etc). I had a similar problem when mapping my Cobb Street tuner maps. I have a WB, and anytime I seen about 3psi or more, my AFRS would go to about 9.0:1! Basically WIDE open dumping fuel, casuing the car to bog.

I tried to flash different maps and the such and nothing worked, changed AFR targets etc, messed with scaling blah blah blah, until I did hard reset, problem went away and never came back. Obviously it was some issue with the ECU, what i have NO idea.
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Old 05-28-2005, 11:12 PM   #6
Justin962
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Yeah, I tried it after I removed my Utec and that is when it worked for two miles then went back to the previous problems. Strange eh?
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Old 05-28-2005, 11:27 PM   #7
hondaeater69
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but aren't you still using modded injectors on a stock map ecu? That in itslef is going to DUMP a crap load more of fuel than the ecu is calling for.


Did you try to pull the trouble codes??

sounds like limp mode of some sorts. Could be the injectors too, did you have them covered and protected since cleaned and flowed?
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Old 05-29-2005, 11:52 AM   #8
phantomsr
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Could be a faulty MAF sensor too. Once you exceed a certain flow rate it reads too high and is fueling for the wrong load site? Just another idea anyway. And if you still have the modded inj with the stock mapping you'll be too rich for the ECU to compensate for.
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Old 05-29-2005, 03:46 PM   #9
Justin962
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2004 WRX Sedan
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Yeah, I was expecting the same problems when I took off the Utec, but was shocked that it worked for the first two miles. Do you think the ecu was learning during that short time? I tried resetting the ecu once again and came up with the same conclusion.

As for the injectors, there was a short period where they were not covered. If I had to guess, it was 2-3 days. Think that could be the source of my problem? Some dirt/grime got in there and is causing it to just dump fuel even though the Utec is trying to control it?
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Old 05-29-2005, 07:38 PM   #10
Wheeler Bement
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Are the TGVs in the right position?

also, how can you tell that the car is dumping fuel? I'm not doubting you, I'm just wondering how you know.
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Old 01-07-2006, 05:00 PM   #11
Paulie V
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Quote:
Originally Posted by phantomsr
Best way to find a leak anywhere in the intake is to take off the airbox and toss a plug in the inlet or MAF hose. Grab a compressor and pump air into the intake, I use the BPV line. If there is a leak anywhere from the heads to the intake you can hear it. Much easier than trying to hear a small leak over the engine noise. Just make sure you watch how much air you put on and stay under 20 PSI or so.
Bump- trying to find an intake leak in my car, but I can't find the right size plug. Someone else used a 2" PVC elbow and endcap, but he had a Perrin turbo inlet hose, which has a 2.75" ID that the 2" PVC elbow fits nicely in. I'm trying to use the stock flexible hose right after the MAF sensor, but it's got an ID of 3". What is everyone using for a plug for the stock intake and where do you find it??

Thanks for the help.
Paul
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Old 01-08-2006, 02:45 PM   #12
Paulie V
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PSM- Cobb Stage 2- again!

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Nevermind- I used some 3M adhesive putty to fill the gap between the hose and the OD of the 2" elbow. Worked like a charm, but unfortunately, I still don't know where the air leak is- sounds like it's coming from UNDERNEATH the intake hose (intake manifold gasket, TGV gasket, etc???) Dunno...
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