Really need help from the KA guru's...

[HolyShiznit]

Well it's been a long process but I thought that my rebuild was finally over. I went to the dyno today after spending all week driving all over to put miles on the new engine. The results...well, I think dyno's hate me. Here's the problem(s):

Weird surge coming from either the compressor or the wastegate just as it rolls into boost. Have no idea why or how....it causes a massive flutter and boost jumps up and down a couple PSI but if you hold through it, it eventually boosts normal. Problem is by then you have already wasted 1.5-2thousand RPM from about 28-3500 rpms. This also causes drivability problems. I can't maintain a constant throttle position unless I am at wide open throttle. Cruising on the freeway is espeically bad because I have to let off, then speed up, then it surges, then let off, then speed up, etc. BOV IS NOT CAUSING THIS. BOV acted like it's supposed to on the dyno and it didn't open early/late.

It won't stop running rich. I am talking BAD rich around 8-9:1. SAFC doesn't do a thing to it. I took the settings on the SAFC to -20% and it didn't do a damn thing. The fuel pump makes a VERY whiny noise and I don't know if that could be related.

I have a 52lb program on the JWT ecu running 1 bar. I have a Tial 38 mm wastegate with a 1 bar spring. The only thing that I changed after the rebuild was a ported and polished head and manifold....I also removed the butterflies from the manifold. I don't know if this could be causing part of the problem *shrug*.

I will get my sheets posted and up so you guys can try to help me figure it out. Feel free to ask away, because I am racking all over for ideas.

[Redline240]

How sure are you that you have the safc is hooked up right? And the settings are correct? i can't see a port/polish causing things to go that rich...did u change your maf? Basic stuff but it all gotta be asked first to get it outta the way....

Redline

[HolyShiznit]

I was running on an SAFC tune at .6 bar before I dropped in the new fuel rail/injectors/and JWT ecu. Then the engine blew, and then here we are. So the SAFC has to be working. It also is correcting for my open atmosphere BOV so it is doing something. And a port and polish would cause it to run lean if anything, not rich. The maf is a Z32 that was hooked up 9 months earlier when I was running on the SAFC tune. Only thing that was changed was the head/manifold/ecu/injectors and boost spring.

[HolyShiznit]

I stumped everyone? I still can't figure it out.

[crzycav86]

Are your injectors in good shape? If they're leaking really bad, they'd drop your a/f a lot..

[:: orion ::]

Sounds like a boost leak...have you pressure tested it yet?

- Brian

[HolyShiznit]

I am doing that as we speak Orion, it's a time consuming process and it doesn't help that college just started up. But thanks for your opinion because that's what I was suspecting too.