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Old 08-05-2008, 05:28 PM   #61
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Stephanie: I think it is not the FMU itself but the check valve that is making this noise. But currently I have bigger problems as you may read above.

I picked up the car to tow it to it's home just an hour ago and we tried and managed to start using throttle application. Engine seems fine at this stage, the turbo however makes alien metallic noises. I will upload videos I captured to YouTube and post them here for your diagnoistic expertise (or banter).

Stephanie: will e-mail you the YouTube links.
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Old 08-05-2008, 06:05 PM   #62
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Normally an intercooler hose blew off the car dies and you cannot start it.

The airflow meter measures no air... So the engine wo'nt start.
At 5.5psi i doubt any engine failure.
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Old 08-05-2008, 06:13 PM   #63
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Video's:




Now what?
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Old 08-05-2008, 06:15 PM   #64
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Quote:
Originally Posted by Spookyfish View Post
In my manual it says:

Check the “atmo” fuel pressure: With the fuel pressure gauge installed in the fuel line leading to the fuel rail,
observe the fuel pressure at idle. It should be between 35 and 38 psi. Blip the throttle a bit and the fuel pressure
should rise and fall a couple psi.

Im around 5.5psi now. So my idle is ok..

BTW, found the coolant leak: where one of the heater hoses connects to the metal pipe that goes below the manifold.
That is correct, stationairy will be 35-38, until you disconnect the vacuum hose going to the stock regulator. (the stock regulator acts like your on full trottle and rises the fp) That is your setpoint.

The 5.5psi boost x 6 psi/psi= 33psi.
The fuelpressure should be (setpoint, around 45) 45+33=79 psi.
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Old 08-05-2008, 06:23 PM   #65
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Yeah, disconnecting gave me 50psi. So FMU was pretty well sorted.
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Old 08-05-2008, 06:26 PM   #66
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Ist things first. CHECK ALL PIPING beween airflow meter and turbo.
Even with a deffect turbo the car runs (idles) like stock.
Not crappy like this...

All 100%???


Can you remove the heatshield from the intake??
Remove the intake and feel the shaft off the turbo.
Does it rotate freely?? No play over 1mm???
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Old 08-05-2008, 06:33 PM   #67
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sound like something inside the manifold touching the blades off the turbo....could be the intake side too....
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Old 08-05-2008, 06:36 PM   #68
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The piping is ok. Maybe the engine killed the turbo. I don't know yet. I'm waiting for more comments and insight from BEGI. Will dismantle the air intake tomorrow.
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Old 08-05-2008, 06:41 PM   #69
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Check the wheel if it turns free...I have a feeling you dropped something in the compressor side off the turbo. (10mm nut...)
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Old 08-06-2008, 06:16 AM   #70
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Well, the compressor side has been opened up now. Picture and video:

(Video is still processing, so it will take a few minutes)

There is virtually no play on the compressor wheel, certainly less than 1mm.
Attached Images
File Type: jpg 06082008.jpg (36.7 KB, 98 views)
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Old 08-06-2008, 09:02 AM   #71
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Ok so the turbo looks ok bij feeling.

The audible metal moise is coming from the turbo???
Still feels like something is in the way off the turbo blades....Could be exhaust or intake...

Remove the turbo and check if something is in there. Check the manifold too.
I know it is a lot off work (and hot today)

Strange that the car is running so bad...I think you still have a vacuum /boost leak.

You can try to pull sparkplugs when idle. 1 at a time or youll be fried too..
Iff 1 off these plugs have no effect (dropping idle) report back.
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Old 08-06-2008, 09:58 AM   #72
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where is the metallic pinging noise coming from? idle the car with the intake off, does it spin well?
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Old 08-06-2008, 10:00 AM   #73
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Quote:
Originally Posted by Spookyfish View Post
Yeah, disconnecting gave me 50psi. So FMU was pretty well sorted.
but what was the fuel pressure in boost? just because the preload was set correctly, doesn't mean it was clamping down in boost.
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Old 08-06-2008, 10:20 AM   #74
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Ok, turbo is off now:


No obvious signs of damage. Wheel turns OK I think.
Attached Images
File Type: jpg 06082008(004).jpg (26.2 KB, 98 views)
File Type: jpg 06082008(002).jpg (63.2 KB, 100 views)
File Type: jpg 06082008(001).jpg (26.1 KB, 96 views)
File Type: jpg 06082008(003).jpg (26.8 KB, 97 views)
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Old 08-06-2008, 10:33 AM   #75
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Quote:
Originally Posted by Braineack View Post
but what was the fuel pressure in boost? just because the preload was set correctly, doesn't mean it was clamping down in boost.
Claming the return gave over 80psi. Am I missing something?
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Old 08-06-2008, 10:35 AM   #76
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Look inside the manifold.. Shake the turbo (don't drop it)
Something must be loose inside there...
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Old 08-06-2008, 10:41 AM   #77
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Quote:
Originally Posted by Spookyfish View Post
Claming the return gave over 80psi. Am I missing something?


so you know your fuel pump can make 80psi in the rail. did you have 80psi when you were boosting?

It sounds like you adjusted the preload correctly. This meaning that the FMU, once it sees boost, is ready to up the pressure from 50psi it was set to. But did you adjust the needle valve to set the rail pressure while in boost?

where is the metallic pinging noise in the videos coming from?
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Old 08-06-2008, 10:50 AM   #78
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Quote:
Originally Posted by greddymx5 View Post
Look inside the manifold.. Shake the turbo (don't drop it)
Something must be loose inside there...
Nope... I shaked the turbo pretty well... nothing.
The axle from the turbine site can be pulled out very very slightly (< 1mm) but I suppose that is normal too?

I will e-mail Stephanie to get BEGI to help me with diagnostics.
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Old 08-06-2008, 11:04 AM   #79
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Noise is comming from the Turbo, or so it seems. But it's off now so I can't retest.
Since I have the oil and water feed + return loose now, I can't really test anything.
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Old 08-06-2008, 11:05 AM   #80
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Quote:
Originally Posted by Braineack View Post
It sounds like you adjusted the preload correctly. This meaning that the FMU, once it sees boost, is ready to up the pressure from 50psi it was set to. But did you adjust the needle valve to set the rail pressure while in boost?
Needle valve was closed (in) so I should be rich at least?
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