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Old 07-08-2012, 09:36 AM   #1776
dexterous
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Did you see the question I was asking about the injectors and rails? When I first installed the rails I didnt put an insulator on the upper part of the injector. When I went to plug the wire harnesses into the injectors (after installing the entire manifold assembly on the engine) I noticed that the injectors could be moved around 1/4 inch up and down. There's no way that the bottoms would hold pressure so something was obviously wrong.

I had a set of injectors out of an 2002 wrx so I compared the two to see that the stock injectors had an insulator at the top seat where they mate to the fuel rail. I pulled the insulators off the wrx injectors and put them on the ID2000s to see if that made a difference. That made them fit much better but I am worried because the body on the ID2000s is not squared off like the stock injectors. I could easily see the ID2000s sliding around when the rubber insulators get hot.

No insulators (look at the contour of the injector bodies):



With insulator installed:
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Old 07-08-2012, 12:56 PM   #1777
02WRX2.5
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use insulator
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Old 07-08-2012, 01:48 PM   #1778
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You can buy packages of universal injector insulators at autozone or most part stores that's what I did. I just went through them and found the rite combination
They need to be lightly compressed just enough that they feel snug when you wiggle them side to side but not so tight that they can't be moved
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Old 07-08-2012, 02:26 PM   #1779
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I spoke with Dex today. It seems the injectors are missing the insulators from the manufacturer. I am sending him out a replacement set tomorrow.
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Old 07-08-2012, 05:27 PM   #1780
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Quote:
Originally Posted by dexterous View Post
I did find something of interest. The drivers side (the side with the blackened plugs) had extra fuel residue in the intake ports of the head when compared to the side that seems to work. This tells me that my problem is likely fuel related. The other side is a normal silver looking color:

Fuel alone would leave a clean surface not one with carbon deposits like that. Improper cam or ignition timing may cause combustion product to back up out through your intake valves creating that residue you see. At least that's my theory.
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Old 07-08-2012, 05:46 PM   #1781
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I would have to agree with cam timing.

Tom, ever find out if your AVCS solenoids were still in good working shape?
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Old 07-08-2012, 06:43 PM   #1782
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Quote:
Originally Posted by bubba2533
I would have to agree with cam timing.

Tom, ever find out if your AVCS solenoids were still in good working shape?
It could just have been the Hydra not controlling the avcs properly
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Old 07-10-2012, 12:09 AM   #1783
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I swapped avcs solenoids and it didn't make any difference. Just in case, I have two new AVCS cam gears coming. As I said, the passenger side head inlets were 100% clean so that's just another sign.
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Old 07-15-2012, 09:03 PM   #1784
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Lots of progress today, here's where I am at:

New IAT and MAP sensors installed and wired up
The mechanical parts of the car are 90% back together
The TGVs and intake manifold are back together
The fuel system is 50% back together (waiting on parts)
About 50% of the electronics have been converted back to stock (wire harnesses, etc)


The remaining steps are:

Reassemble the exhaust
Re-install the top mount oil cooler
Re-install the accessories on the front center of the motor (alternator, etc)
Remove the Hydra
Remove the Hydra's custom harness
Remove the Meth system electronics (leaving the wires in place)
Wire up the boost switch for the fuel system
Tape off and secure any wiring that will remain in the car

Again, the plan here is to leave the wiring, meth plumbing, etc in the car so that I could easily return to the Hydra/Hydramist in the spring.


The best news of all is that I have an appointment with a tuner from a local shop to come to my house and help me start the car on Thursday. The plan is to get a 93oct pump map together on my Access Port so that I can finish my break-in. Once I have around 1500 miles on the car (sitting at ~700) I will have the same guy come back to my house to finish up my pump gas map. Basically, I only want a quick 93oct pump gas road tune that would allow the car to be run at WOT to 7000 RPM on wastegate boost. There's no power goal for that map, just a well running car that is very very safe. After that I plan on getting the car dyno tuned on E85 and then the game is on!
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Old 07-15-2012, 09:07 PM   #1785
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Quote:
Originally Posted by shilohb View Post
It could just have been the Hydra not controlling the avcs properly

Unlikely. I pulled the connectors off the AVCS solenoids and ran the car for a while (at Phil's request) and it made no difference.
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Old 07-15-2012, 09:16 PM   #1786
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Then there are only three other places it could be cam gear, avcs solenoid, or defective wiring
My fuel lines are run the same way
I have 10- to a y that goes to 8- then fuel rails, to fpr a1000 in on each end then back to surge tank with 8- and I have no problems
Also I'm not saying hydra is bad I wish I could still run it also but there is no one local that wants to tune on it
The other problem I had with hydra was the wire adapter did not make a good connection on a couple wires and I had to hunt that problem down..
It was for my throttle by wire maby you had a bad connection at the wiring going into the Hydra leading to a uncontrolled avcs and that's why unplugging it made no difference
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Old 07-16-2012, 01:42 AM   #1787
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Correct myself it could also be a oil feed issue.. so four things it could be
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Old 07-17-2012, 10:33 AM   #1788
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I'm glad the AP worked for you last night and I look forward to seeing the car this weekend! Keep us posted!
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Old 07-17-2012, 02:13 PM   #1789
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Great thread!
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Old 07-18-2012, 01:07 AM   #1790
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As Moore Performance mentioned, I finally got my second hand AccessPort here and working. There was a bit of a misunderstanding on the sellers behalf about uninstalling it from his car. It's all good now and that's what matters.

I also finished up my fuel system which turned out pretty well. Buddsautoparts.com helped me get two fittings from aeromotive that allowed me to re-use my expensive goodridge 910 fuel lines without any modifications.

At this point I need to finish up some wiring work, put the alternator back on and install the mid-pipe in the exhaust. I should be able to get this all done tomorrow as I have the tuner coming on Thursday. I am really trying to get the car to the largest car show/meet in Pittsburgh which is coming up this weekend. With a little luck I will make it...
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Old 07-18-2012, 01:10 AM   #1791
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Fingers crossed Tom, hope things come together nicely.

My car is on the base map tune now, 375whp on 14psi no meth. Should make for some healthy 500+ numbers when she gets fully tuned!
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Old 07-18-2012, 01:50 AM   #1792
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My cars running too...your determination will pay off brother.
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Old 07-19-2012, 01:54 AM   #1793
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Update:

Its 12:46AM here and the car is back together and ready to start! All the mechanical and electronics work is done which took a really significant amount of work. The tuner is arriving at 11AM now (we pushed it up) so we should know in a matter of hours. He is pretty confident that he will be able to tell if there are issues still present very quickly. I gave him a pretty good description of the issue and he is bringing a few spare parts just in case.

Here's a few picts:

The Engine Bay (not much of a visible difference):


Here's what a $30 -6 ORB to -6 90 degree swivel fitting looks like (drivers side return):


A quick shot of the fuel line and rail on the drivers side


The -6 union that allowed me to re-route the passenger side fuel lines:
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Old 07-19-2012, 02:36 AM   #1794
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Fingers crossed again for you mate
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Old 07-19-2012, 03:46 AM   #1795
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That is one clean looking engine bay
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Old 07-19-2012, 01:28 PM   #1796
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Tuner is here and so far it seems ok. I wont say its working but I will say that its not "not working". I will say that I am impressed at the idle of the ID2000s on 93oct.
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Old 07-19-2012, 02:00 PM   #1797
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Quote:
Originally Posted by dexterous View Post
Tuner is here and so far it seems ok. I wont say its working but I will say that its not "not working". I will say that I am impressed at the idle of the ID2000s on 93oct.
This is using the AP now correct?
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Old 07-19-2012, 07:00 PM   #1798
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Quote:
Originally Posted by binjoau View Post
This is using the AP now correct?
Thats correct
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Old 07-19-2012, 07:10 PM   #1799
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The tune lasted about two hours and I think things went pretty well. The car has a few driveability issue but nothing that crazy. As far as the tuner can tell, there doesn't appear to be anything wrong with the car which is really good news. The AVCS system appears to work perfectly as both cams are typically at the exact same position (sometimes they vary slightly). The new fuel system routing also appears to be pretty good as thats all working well too. My idle is now very smooth but as others have predicted, it idles fairly rich with 2200cc injectors.

Last edited by dexterous; 07-19-2012 at 11:38 PM.
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Old 07-19-2012, 07:23 PM   #1800
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Excellent news Tom, really happy for you. I didn't think a perfect idle could happen on 2000cc injectors lol.

What's your typical AFR right now?
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