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Old 12-28-2005, 12:12 AM   #1
legacy2003
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Default problems with sti/wrx hybrid setup. help!

i also posted this in the factory 2.0L turbo forum, but i'm not sure where i'd get more replies, so i decided to post this thread here as well.

i recently blew my 02 wrx motor in my 00 2.5rs (swapped). i replaced it with a known working 04 usdm sti bottom end, with 02 wrx heads and usdm sti cams. motor was fully assembled and had 6k miles on it when i picked it up. we just had to put the timing belt on. my full setup consists of:

-04 usdm sti block
-02-03 usdm wrx heads
-usdm sti cams
-16g turbo
-ultimate racing 785cc injectors
-walbro 255lph fuel pump
-gpmoto tmic
-txs bov
-perrin short ram intake
-sti up pipe
-erz catless down pipe
-stromung 2.5" catback
-txs utec

i had brought it to franz @ ktr performance in massachusetts to get tuned this past thursday. he was expecting about 270 whp on their "heartbreaker" dyno dynamics dyno. however, he couldn't even tune it past 210whp @ 17 psi because my knock count was in the 30's. we couldn't figure out what was going on with it. the car still knocks even detuned at 16psi (1 or 2 knock counts now), and i experience all sorts of hesitation, and a rough idle. i'm not sure what's going on with this thing. i'm scared to say the least because i don't have any more money left. i see some smoke @ wot coming out of the exhaust.

we hooked up a laptop and my a/f ratios look okay. what else could be causing knock? we put the motor into time and we cranked it over 4 times and it was in sync the whole time, so i doubt that is an issue. we're going to check it again anyways.

i did manage to get in contact with the original owner (there's a long papertrail with this motor, i had bought it off a someone who never ran it who had bought it off someone else). what he said to my email was:

"I was the middle man on that motor.. It was how ever in great running shape.. It has US STI cams and US STI headgaskets with US WRX heads. The motor was not in an accident, it might have had glass on it from either when I picked it up or from when it was in marks garage. It came out of the car because it was being replaced by a axis/crawford motor, 35r, ect ect.... Im pretty sure the car made like 330hp/350ftlbs with an 1820 on a dynojet. The 210 numbers sound really really really ****ed up.. It is defintly an 04 motor, I know that some 04s did have a bearing clearance issue that would cause oil blowby through the oiling passages and cause it to end up in the intake ect ect.. in turn you will see it in the exhuast and out the back.. That would lower your fuel octane alot as well and cause knock, it could also be the tune... but from what I undestand the KTR guys are pretty good.. Have you checked all the obvious stuff? what AFR are you running, etc etc. I would just do a leak down, compression numbers will be fudged because of oil in the pistons... Maybe the timing is off? Check belt timing, if timing is off you could have slight valve contact and have bad sealing on the valve seat..."

could this blow-by issue be causing my knock? how do i fix it?

btw, i also have another question... the sti block has 2 outlets for hoses to run oil into the avcs heads. obviously my heads don't have avcs. the previous owner had put breather filters on the ends of these metal hoses on the block. those hoses spit oil, and it drips onto my turbo and burns off, and also drips onto the ground. what would a good solution be for this? could i just take a piece of hose and loop the 2 outlets together, or should i cap the ends?
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Old 12-28-2005, 12:40 AM   #2
TexRex2002
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Well, in my first hybrid build I had a loose ground wire that was jiggling around and sparking, sending the knock sensor off... might be worth checking (for me it was the one that bolts to the intake manifold). my car exhibited exactly your symptoms, btw, except that I didn't dyno tune or go past 10 psi in that condition.

Also, when you have rod bearing problems it knocks like a mofo (let's hope it's not that).

the two oil nipples are not for AVCS, they are crank case pressure relief vents. you should plumb them into the PCV valve on the intake by the throttle body, or hook them into a catch can.

hope this helps a little...
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Old 12-28-2005, 12:58 AM   #3
legacy2003
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Quote:
Originally Posted by TexRex2002
Well, in my first hybrid build I had a loose ground wire that was jiggling around and sparking, sending the knock sensor off... might be worth checking (for me it was the one that bolts to the intake manifold). my car exhibited exactly your symptoms, btw, except that I didn't dyno tune or go past 10 psi in that condition.

Also, when you have rod bearing problems it knocks like a mofo (let's hope it's not that).

the two oil nipples are not for AVCS, they are crank case pressure relief vents. you should plumb them into the PCV valve on the intake by the throttle body, or hook them into a catch can.

hope this helps a little...
cool. now, if i have rod bearing problems, would there be any way i could tell this (ie engine noises or smoke or something like that)? i'm really hoping that's not the problem. this motor does sound VERY healthy, and it has very low miles on it, but i'm not shunning any possibilities yet.

btw, pertaining to the knock sensor, i know it's working properly, as the utec tells me how much knock there is, and that it is knocking and everything. is it possible it might still be screwed up as far as the ground goes?
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Old 12-28-2005, 01:13 AM   #4
TexRex2002
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If the motor sounds really good it is unlikely that you have a rod bearing problem (they sound really crappy then).

The knock sensor worked for me too (showed up in the utec and everything), just that the loose ground was causing the sensors to go wild (all the sensors were giving odd readings).

COUld you post a utec log please? That would aid in the diagnosis.

Don't be getting any more 30 counts though...
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Old 12-28-2005, 01:16 AM   #5
Subie Gal
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crossposting is not permitted here

please dont do that...

pick one forum and stick with it.
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