Hi Guys,



Bear with me this might be one of the longest post yet



I did a rebuild with a Rotary aviation Master rebuild kit..My old engine had a scratched housing and a broken seal.. I also replaced the scracthed housing.... then i drove the car for 800 miles without boosting and keeping the RPMs below 3000...



After 800miles of run-in i gave it a little throttle to see if it boosted.. and it was boosting fine till 4-5 psi so i stopped.. the vaccum was a little low at around 350mmhg but my car is streetported...then after another 200miles i floored the accelerator at around 3500 rpms.. at 8 psi around 4500rpms my car started hesitating.. like something was stopping it and made some load noises from under the hood felt like something was holding it back.. so i stopped...



I thought my turbos must be shot.. so i bought a single turbo kit from a friend.. it has a custom manifold, an HKS T04E turbo and a Turbosmat pro-gate wastegate... after installing the kit i drove the car for a little while without boosting... then i boosted but at around 8-9 psi at around 4500 rpms the same problem occured....



The i asked some ppl and they said i might have the wastegate hooked up wrong.. so i got the diagrams and hooked it up correclty.. then took the car for a spin.. it ran great..i just gave it a test run and parked the car.. the next day i was very busy so i just gave it another test run and parked it again.. then i asked my mechanic to come by my house in the day and take the midpipe off and put a resonator in it.. the problem came back.. now i have taken the resonated midpipe off and have the straight through mid pipe in.. still the problem is there.... what could it be.. following is a list of the mods :



Streetported motor

HKS T04E turbo kit

Greddy large SMIC

Apex-i GT spec Radiator

Apex-i N1 Exhuast

Apex-i Power FC

Greddy E-01 boost controller

Midpipe

Aquamist 1s system





Any clues on what it could be.. also when the hesitation happens i can hear the wastegate popping it makes loud noises and at time it gives a sound like an explosion... and severe hesitation..



Please Help https://www.nopistons.com/forums/pub...O_DIR#>/11.gif

What broke the last engine?

did u ever tune the car??

What size injectors are you using? Is the FPR connected properly? On the Power FC did you see high injector duty cycles, was the knock level high?



What are the boost cut settings on the Power FC?



Really need some more information to figure it out, It could be fuel related or it could be a limiter setting on the Power FC.

sounds like he's hitting a rev limiter and/or the ecu is set so rich that banging sound you hear is fuel over-run.

Sounds like tuning. Find someone who can give you some maps or help set it up correctly.

Quote On the Power FC did you see high injector duty cycles, was the knock level high? /Quote



When the one day it ran fine at 13 psi i saw 96%.. else it hesitates at even 60% duty cycle.. I am using stock injectors..





Quote What are the boost cut settings on the Power FC? / Quote



I don't know.. are they the ones which say primary and secondary.. those i have set at 1 bar..





Quote sounds like he's hitting a rev limiter and/or the ecu is set so rich that banging sound you hear is fuel over-run. /Quote



Feels like it too.. when i hear the bang it feels like its hitting the limiter or something...





Ok now i remeber ever since i put the single turbo in the car it is running richer.. the o2 sensor always read rich... the exhaust air is signifcantly cooler.. i don;t have an EGT but it feels cooler if i put my hand infront of the exhuast..Also after a run if i park the car and then start it up again.. it starts right away but it starts like its flooded a little.. takes atleast a minute to idle properly..



Can it be the FPR... should i try using an aftermarket FPR??



About the maps.. i am not sure if they are the problem as i was using the same powerfc on my car before the rebuild on the old engine .. and it was boosting fine...



Please help...Thanks

Ok reset the ecu.. drove the car and it felt much much better... i ran like 2-3 3rd gear runs uptill 5500rpms at around 9 psi.. all was fine...



then after i parked it and then drove it at 9 psi it would again hesitate a little... so i turned the boost controller off.... now at 6.5 psi it runs great.. no hesitation..



Can it be the boost controller... it does make some strange noise too..



at 6.5 psi i drove it for half an hour without any problems to 6500rpms...



Ok this is what i do.. when i park the car i let it idle for 1 minute and then turn the engine off but keep the ignition on so that the fans would stay on.. i let the ignition on for 40 mins and after dinner went back to take the key out and monitor the max water temp on the Commander... to my surprise it had reached a max of 108c



Isn't that a alittle higher than it should be?



Should i try a manual boost controller?



thanks

i honestly honestly think its ALL tuning related. You are a brave man to slap a single turbo on your car and run around boosting on stock injectors without a thought at to what the maps are. Tuning issues could cause any number of problems to cause the car to react as you described.

another possibility is that its a bad harness or wiring.



it does sound like its either detonating, or hitting a fuel cut