410 replies to this topic

[LukeFranky]

Yeah, it is a MY03. EJ208. I'll write up a build thread with pics and the whole story once I get it running right.

 

Diagnosis of the lean/rich condition has been put on hold. I pulled the gearbox out to put my new clutch in only to discover that both the rear main and the gearbox were leaking oil onto the clutch. My old man is going to split the gearbox open for me to fix the leak and replace a ton of bearings at the same time.

 

Anyway, here's the condition of the old clutch...

Attached Files

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[duncanm]

oooh eerr - lots of gunky black sticky shit on there.

[Jimbo]

There's your problem! It's good to know when it's all out you can repair it all. Hopefully the "other" issue is handled soon too!

[Robbks]

*cough*
you know what to do while the gearbox or engine is out and you have good access to the rear of the motor...

[LukeFranky]

Update: We're in action again, sort of.

 

I put in a new gearbox and HD clutch. Bit annoyed that the gearbox isn't in as good condition as I hoped. Some of the syncros aren't great.

 

Anyway, I'm back on the road and can get to finally sorting out this P0171 problem. I haven't yet had a chance plumb the PCV back in or redo the gaskets on the intake manifold, but the car has presented new symptoms...

 

When cruising the highway under low boost I can feel the car surging every few seconds. My boost gauge collaborates this, pulsing up about 3 PSI for a second then dropping back to where it was. I now also can feel a slight misfire on idle.

 

I'm hoping it is just an air leak from dodgy intake manifold gaskets that has opened up even more.

 

 

Side note:

I've been having problems with my intercooler knocking against the fire wall. I have a replaced the engine mount that lives below it and it is still sitting too close. The exhaust was also knocking just after the cat but that's been fixed with some encouragement from a big metal bar and a gas bottle

Anyone had this problem before? Bit worried that the car may have been in an accident and everything might be out of whack.

[duncanm]

without PCV plumbed up - won't your intake air measure be all out of whack?

 

Can't help with the intercooler - mine is ok even with an inch of body lift (ie: motor 1" lower in bay)/

 

Have you snugged up the pitch stop in the right spot? 

[LukeFranky]

I have a bluetooth scanner that sometimes lives plugged in. Sadly the only live data I can get from it is battery voltage, but it does do a good job reading codes.

[Robbks]

As I said about 15 posts ago.
get rid of that silly pod and MAF pipe for a start it will not be helping your troubleshooting.

you've also got a heap of new vac lines in place and have probably ended up deleting at least one restrictor pill.

As for the PCV, that won't be helping things at all either.
Get that sorted and all the factory plumbing back to where it should be.

If you know your intake manifold is leaking, ensure that's done too.

there's no use trying to diagnose an airflow issue when you have other airflow issues.

while you're pulling bits apart, make sure you're cleaning and inspecting each and every hose, solenoid, joiner, etc to make sure it's 100%
check any hose clamp and pipe is properly connected and none of the bends are cracked/ leaking air.

until all of that is done, there's no point trying to fix anything else on these engines

[LukeFranky]

As I said about 15 posts ago.
get rid of that silly pod and MAF pipe for a start it will not be helping your troubleshooting.

- I can't, unless I source an original filter box. Car came like this and didn't come with the old parts.

 

you've also got a heap of new vac lines in place and have probably ended up deleting at least one restrictor pill.

- Checked and rechecked.

 

As for the PCV, that won't be helping things at all either.

Get that sorted and all the factory plumbing back to where it should be.

If you know your intake manifold is leaking, ensure that's done too.

- Already planning to.

 

there's no use trying to diagnose an airflow issue when you have other airflow issues.

while you're pulling bits apart, make sure you're cleaning and inspecting each and every hose, solenoid, joiner, etc to make sure it's 100%
check any hose clamp and pipe is properly connected and none of the bends are cracked/ leaking air.

until all of that is done, there's no point trying to fix anything else on these engines

- Not trying to diagnose anything new. Maybe the new symptoms might help create a clearer picture of the original problem.

 

 

Does it bother anyone that I keep this thread up to date? I might be too optimistic, but maybe it will help someone with similar symptoms one day.

[Robbks]

- I can't, unless I source an original filter box. Car came like this and didn't come with the old parts.

 

Step 1
Stock filter box and AFM housing,

they are not a restriction to airflow anyway, and you won;t be sucking in hot, dirty air from the engine bay, you'll get cool clean air from the inner guard

[allpaw4]

Getting one out of a wreck is your best bet at sourcing one quickly. Other than that, import monster.

[LukeFranky]

Pulled the intake off. Put new gaskets in. Plumbed up my PCV properly (thanks Kong).

When I put it all back together and started the car I was quite alarmed as it immediately started knocking. The sound disappeared quickly. I didn't drop anything down the intake as far as I'm aware. Could it be because I fixed the air leak the car was running right out of whack before adjusting?

On the first drive the engine light came back on, but turned out to be the cam shaft sensor. The car has had earthing problems in the past and I had an extra earth attached right near the cam shaft which I had left unattached. Thinking about it now, could this be another reason why the engine started knocking?

Anyway, reattached the additional earth and the car has been running much better with no error codes.

However, the recent surging problem still exists. It occurs when I sit on low boost. I do have the BOV plumbed directly to the manifold. Might take it back to stock to see if this resolves it.

Regardless, I'm a happy man. My major issue has been sorted. Thanks all!

[duncanm]

good news!

 

Yeh - not surprised the car knocked and kicked like a bronco on startup if the cam sensors were playing up.  Start + dodgy ground = low voltages.

[allpaw4]

The B4's will surge on low boost, especially when sitting on the edge (around 0 psi). I found I could make it start it if I held the throttle in that perfect spot to hold 0 pound, and it would just start surging like nothing else. All of a sudden you'd be doing illegal speeds.

[LukeFranky]

Mine never used to surge. Only started since I put the new gearbox in a week ago.

[Jimbo]

The B4's will surge on low boost, especially when sitting on the edge (around 0 psi). I found I could make it start it if I held the throttle in that perfect spot to hold 0 pound, and it would just start surging like nothing else. All of a sudden you'd be doing illegal speeds.

This makes sense to something I experienced a few weeks back highway driving.

Hold it on 0psi at freeway speeds and it starts shuddering a bit. It was either that or as Dunc described the Auto lock-out. Probably the latter as my tranny probably needs a good service.