Horsham Stage 3 chip in-place, but still early cut out..what could it be??

[JDMSIL80]

Some of you have already chime in my previous thread regarding the early cut-out issue: zer...age=1

After doing some research on the Horsham chip, I decide to give a try since i am running the exact mods needed for the Stage 3 chip. Its program is designed for running bigger fuel pump, while maintaining stock FPR. I figure this chip should be the link I need to get the car running properly.

So I installed the chip today, hoping it would bring an end to the cut-out issue which has been happening. The car started up just fine, and the power is noticeably better at each boost level (7 to 12psi) than I was running Power FC (map not fully tuned). The car never felt as lively as before, the power is much smoother and stronger with this chip.

I increased the boost to the 13psi and floored the throttle at 2nd gear, the power was there as it pushed me from the seat but once i hit 6500rpm it cut out on me again!!! I tried increasing the boost to higher level, the cut out comes on even earlier!

At this point, I'm getting quite paranoid because I have already tried a few things that comes it mind: ensure there's no boost leak, gapping down the plugs, better coils (FET coil pack), ideal ecu chip.

However, the problem never got away! There must be something I've overlooked, but what could it be?

On the bright side, the Horsham chip is giving me a lot more power for daily driving. But the cut-out issue really destroys the fun when you step in the throttle. Besides, I have already purchased set of HKS cams. Its really a waste if I cannot rev the motor up, hopefully you guys can help me dig out the problem.

Here's my mods list:

Z32 MAF444cc injectorsGT28RWalboro 255Blitz ID-color boost controllerBlitz gauges (pres, EGT, boost)FMICTubular manifold3" turbo backHKS filterFET coil pack

For more info on the Horsham chip, refer here: http://www.h-dev.co.uk

[kota2240]

what you are describing is something similar to what i had. Did you take out the spring in the rubber intake tube.? This caused the intake tube to colapse at higher rpms since it was pulling in so much air. Put the spring back or get a aluminum intake. I wasnt the only one with this stupid problem

[mikesim]

pump + 444cc - FPR = bad

you may be overrunning the stock FPR. you should really stick a wideband on there to help you along with reading the EGT for proper tuning.

[JDMSIL80]

I am still running with stock rubber intake tube attached between the turbo and Z32 MAF.

But which spring are you referring to? Do you happen to have a picture of it because I don't recall seeing a spring on mine.

what you are describing is something similar to what i had. Did you take out the spring in the rubber intake tube.? This caused the intake tube to colapse at higher rpms since it was pulling in so much air. Put the spring back or get a aluminum intake. I wasnt the only one with this stupid problem

[JDMSIL80]

Apparently, the Horshame Stage 3 chip is designed for this combination: Pump + 444cc + stock FPR.

pump + 444cc - FPR = bad

you may be overrunning the stock FPR. you should really stick a wideband on there to help you along with reading the EGT for proper tuning.

[Not_a_sr]

thought you bought a power FC?

[JDMSIL80]

I did, but never got around to tune it because of the cut-out issue.

So I purchased the Horsham Stage 3, since its most suited for my existing mods. Hoping that it will solve the cut-out problem too....

I have cleaned the coil packs, springs and changed to new plugs as recommended, but the cut-out still occur.

It cuts me out at 5500 at 14psi, even sooner at higher boost.

Whats next?

thought you bought a power FC?

[Swedish Mike]

Measured the fuel pressure while driving and under boost?

Do you use colder/harder plugs?

Helped one guy with a small air filter one time, gives you the same problems as a weak intake hose.

/Mike

[JDMSIL80]

Did you mean the guy with a small air filter had the same problem? How did he solve it?Im running HKS power flow (150mm), which is the smaller version. But I have tried running without the filter, the cut-out still exists.

I dont have fuel pressure gauge, but am running - 7 heat range plugs.

Measured the fuel pressure while driving and under boost?

Do you use colder/harder plugs?

Helped one guy with a small air filter one time, gives you the same problems as a weak intake hose.

/Mike

[Swedish Mike]

Did you mean the guy with a small air filter had the same problem? How did he solve it?Im running HKS power flow (150mm), which is the smaller version. But I have tried running without the filter, the cut-out still exists.

I dont have fuel pressure gauge, but am running - 7 heat range plugs.

Yeah, a CA guy with a small air filter had problems like this, it got sucked into the MAFS at high boost or revs.We just mounted a big K&N instead, but this is not the problem on your car if you tested without filter.

You should borrow a fuel pressure gauge and tape it on the windscreen.Testdrive and see if the pressure drops.

Also connect a ground wire between fuelrail and ground, bad injector ground will also cause problems.

/Mike

[originalsin]

its more of a metal wire in the stock intake tube, that holds its form so it doesnt collapse. just squeeze it youll know if it theres, youll feel it. but i think it could be more fuel related. running any freshly tuned car without a wideband is very risky, my friend owns a lotus, he bought a turbo kit for it, which came with management, we hooked it up seemed to be running fine, the slapped the wideband on and were heading out for a little road testing and the map's the company sent him sucked as, we ended up redoing them. and this turbo kit was like $8500

but idk, i would get a nismo fpr especially if you got the 255 HP pump, and then just set the fp at stock pressure, its probably not holding fuel pressure once it get up in high rpms. and yes maybe horsham is running fine with it, but every car is different, unless you just getting a chip to run safe and real rich all the preprogrammed stuff usually isent that great and needs some custom tweaking....

thats just my $0.02 tho

[nissanic89]

I did, but never got around to tune it because of the cut-out issue.

So I purchased the Horsham Stage 3, since its most suited for my existing mods. Hoping that it will solve the cut-out problem too....

I have cleaned the coil packs, springs and changed to new plugs as recommended, but the cut-out still occur.

It cuts me out at 5500 at 14psi, even sooner at higher boost.

Whats next?

whats next is to figure out what your problem is and quit throwing away money on parts that arent going to fix it. take it to a competent shop have them give it a once over. check all things mechanical, its probably not ECU related since you have the problem on a powerFC. right now your just blindly thowing money at it and hoping some sticks in the right places. hell give me that money and id done have your car fixed and over 300hp...

[JDMSIL80]

Infact I was inspecting the coil packs tonight by pulling out the red rubber hose off, I noticed the FET coil packs do no have the notch while exposing the coil springs. But on the stock coil pack I was using previously, 3 of them have the notches fully exposed while 1 of the notches looked to be weared out since it does not stick out as much as the other 3. Could this be the problem? I might buy just one coil back from the dealership to try out.

[kota2240]

did you try to see if that spring in your rubber intake tube is there? Its there to keep it from collapsing. The more boost i pushed the sooner my cut out occured and it was because the spring was taken out.

[JDMSIL80]

I took a look but couldn't find any spring, bascially the rubber intake tube is squishy. But then with the Z32 maf and HKS filter in place, it secures the tube pretty well, although its slightly bented downwards because of the weight of the maf and intake and nothing there to hold it up.

did you try to see if that spring in your rubber intake tube is there? Its there to keep it from collapsing. The more boost i pushed the sooner my cut out occured and it was because the spring was taken out.

[kota2240]

take a look inside that intake tube, do you see a large coil or spring anywhere inside?

What do you mean squishy? can you squezze the intake tube fully shut with your hand? If so then thats your problem.

[JDMSIL80]

I'm quite positive there is no large coil or spring inside the tube, does it sit closer to the turbo or the MAF? I'll double check tonight when I get home.

Yah I can squeeze the intake tube fully shut using a bit of force. Is that why??I dont recall seeing being shut close that time on the dyno...but Im not totally sure..

Also, the MAF adaptor connected to intake tube should prevent it from closing under boost. One thing I dont like about the rubber tube is it tends to bend down creating a bottleneck at the bending point. Should I get someone to weld me an intake pipe at this point?? Thanks!

take a look inside that intake tube, do you see a large coil or spring anywhere inside?

What do you mean squishy? can you squezze the intake tube fully shut with your hand? If so then thats your problem.

Modified by JDMSIL80 at 9:34 AM 5/1/2006
Modified by JDMSIL80 at 10:15 AM 5/1/2006

[float_6969]

kota2240 just figured out your problem. You SHOULD NOT be able to collapse the intake tube, AT ALL. AT ALL!!! Get an aluminum intake tube, or build one or something.

[kota2240]

It looks like a big ****in slinky lol. It goes from one end to another as one big piece. Anyways since you said you can collapse the tube, thats your prob.

[JDMSIL80]

^I cant believe this was overlooked from the beginning, thanks for pointing out!! Hopefully this is the missing puzzle.

I'm going to get an aluminum intake pipe welded this weekend, will keep you guys posted.

[float_6969]

Just try to keep the MAFS in the stock location, it's very sensative to it's distance from the turbo. It will get really screwy if you get it too close.

[Swedish Mike]

Want to add, some guys remove this spring because it sometimes suckes in the turbo, you can figure out the result...

This is (with the oil cooler) one of the first things to upgrade on a CA18 IMO.

/Mike

[JDMSIL80]

Thanks for the headsup guys! It will be my last hope to this issue =)

[JDMSIL80]

Found the cut-out problem! It was indeed the rubber intake hose that was closing on me under high boost. Got my intake welded today and the problem went away! Thanks guys for all your help, really happy with the car now

Its running great but not perfect, still having misfire just before your hit boost. And when you upshift aggressively stomping on the throttle, it hesitates and misfire for a good few seconds before the power smooths out again. I have already changed the plugs, coil packs and new O2 sensor, what else should I look into??

[capwred]

make sure your timing is correct.

[M374llic4]

Found the cut-out problem! It was indeed the rubber intake hose that was closing on me under high boost. Got my intake welded today and the problem went away! Thanks guys for all your help, really happy with the car now

Its running great but not perfect, still having misfire just before your hit boost. And when you upshift aggressively stomping on the throttle, it hesitates and misfire for a good few seconds before the power smooths out again. I have already changed the plugs, coil packs and new O2 sensor, what else should I look into??

If you have tunable upgrades like you said that have not been fully tuned, this can definatly cause that kind of reaction. That and if your timings off, big difference. A mixture of the 2 being adjusted and tuned properly will make an even Bigger performance difference.

My friends KADE went from hesitation and mediocre acceleration to chirping 2nd and 3rd with just a timing adjustment.