I need some asistance trouble shooting. A fresh single turbo rebuild. Siemens 850 primaries inj. and bosh 1600 secondary inj (with resistors installed. Previously running OEM 850 primaries and bosh 1600 secondaries (No issues).

The engine will only start with heavy modulation of the throttle (Pumping gas pedal). Will not idle. When running the engine it stumbles and is very rough. Blows Blue / White smoke.

When the throttle is applied 50% and stabalized the smoke reduces. When throttle is removed and held around 2000 rpm it smokes heavy for as short time and settles (still smoking just not as bad). All through this running it is very rough and as soon as throttle position is removed the car dies.

I have checked:

1) Removed spark plugs front and rear and isolated fuel and ignition. Cranked engine and nothing ejected from the spark plug holes. Spark plugs had black carbon deposits and were dry.

2) Verfied correct position of fuel injector harness

3)Verfied correct position of coil harnesses

4) Verfied correct position of spark plug leads.

5) Verified correct position of crank angle harness.

I am stuck and don`t have any idea of what to check next. Need some direction on what is the next step.

 

Aftermarket computer? Sound like you just need a tune. Single or stock twins?....reason I ask? ......is blue smoke is never good... also ....who rebuilt the motor?

 

Blue smoke is generally oil. Whoever rebuilt it may have pinched an oil control oring. Hopefully for your case its the tune and excessive fuel. What settings are you running for the injectors?

 

my first thoughts are MAP sensor or vacuum leak. I wouldn't press the panic button on the smoke yet.

 

considering it takes 50% throttle and isn't pegging redline... do the easiest test first, grab your compression gauge and test the engine's compression to rule out any missing internals like apex seals..

next as suggested double check the MAP sensor line(i had someone install their own engine with a check valve in place of the filter....) followed by the injector setup in the ECU.

 

the blue smoke could also be as simple as the oil being over-filled..

 

so you put a Rebuilt engine in AND rebuilt a single turbo at the same time?
I woudlnt worry about the smoke yet but you need to get that idle under control first

 

Mine smoked like crazy when I was first starting it. I was doing a manual idle control so it was even more of a pain in the ***. My mistake was using someone else's map for the break in. Once I went back to the base map I was able to make my adjustments and the smoke was gone. Do you have a wideband? Mine was super rich in my new idle range.

 

with his 850 primaries it would run like *** on the original maps, but then again that could be his issue here.

 

Things are sorted.

It just was the assembly fluid burning off and the PFC not set up for running a ported engine (RUNNING VERY RICH).

The PFC slowly started to learn and corrected itself while doing so burned off all the excess assembly fluid. Now not a hint of smoke and runs like a dream. Idle is quite low which can be corrected at the tuning shop.

I am a very happy camper. Especially when I rebuilt the motor and had on one to turn to for waranty (if required). Thanks for all the help guys!

Here is a vid of it running
http://www.youtube.com/watch?v=HQ0BLQ-mVVs

 

Holy gauges batman, glad to see its worked itsself out.

 

Do you plan on another rebuild? Not the best idea to be revving an un-tuned motor like that.....

 

So the PFC sorted it's self out initially to cope with the porting issue before it's tuned? Pretty sweet. I'm about to put my ported motor is so this is good info to know.

 

Not a big issue with reving a motor. As long as fuel delivery is aceptable. No Boost reuslts in a very limited posability of pre ignition / detonatnation. No load / no boost.

The map was a design for this set up. Was very impressed with the power of the software incorporated in the PFC to be able to dial in and run this setup.

 

The only thing the power fc will do is attempt to learn the idle. It does not self-adjust for anything else as far as I know and read strictly off the maps programed in. I guess you didn't have to much run time on the motor. All new builds will smoke for a short period while the assembly lube burns off. Drive it easy (low load/minimal boost) and get some milege on it, then get a proper tune.