Ive had my car together for a year now with no issues. Just yesterday I was driving and went to get on it, it felt like I hit boost cut. I turned the boost down and did another pull watching AFR and the car is going lean above 4000rpm in boost. I went part throttle around 10psi and sure enough once I got to about 4500rpm or so it started going lean again. I let the car cool down and went for another drive and this time it stayed rich until about 5500rpm, once I went to do another pull it got lean sooner, around 4500rpm again.

Setup is a Hydra 2.5 w/ DW200 pump and stock NB regulator, RC550's and a radium rail.

At this point Im thinking its got to be the pump going out, Ive read that a lot of people have had issues with the DW pumps failing on them. I'm gonna do a datalog today to see what the ECU is showing. I didnt touch the tune at all, so its unlikely its tune related. I dont think its ignition related because the car drives smooth, idles well, etc. I can visually see the AFR going lean if I stay in it and of course then the car wants to completely fall on its face when it gets super lean. Has anyone had a DW 65c/200/300 fail on them this early? I went ahead and ordered a Whinebro 255 and a new fuel filter so I will update this once I get the new pump in the car and see whats what.

 

My friend with a 04 WRX had been using a DW for a little bit. It kept failing on him after about 1-2 months. After 3 times of DW warranty replacing or repairing it they finally refunded his money. With all the issues I have heard from other people regarding DW products I wouldn't use them.

 

That's a bit anecdotal, I haven't heard of this being an issue with many other people running the same pump. Mine has been perfect for over a year now. After 3 pumps I would assume its something else with the setup.

Back on topic, to me that sounds like your pump is struggling to supply enough fuel that is being asked for. Could be clogged fuel filter as well.

 

Yea, Im replacing the fuel filter along with the pump. The car was literally perfect for a year and this kind of came out of left field. Ill update this thread when I put the new pump in. If that doesnt fix it then more diag will be necessary.

 

Yeah I think they fail pretty quickly when they go. Could also be the afr sensor? Seems less likely though than the pump. Might be able to tell from the logs by looking at the PW? I have no real idea though, hopefully someone more experienced chimes in.

 

It's not the AFR sensor. He already stated that the car falls flat on its face when he gets into boost. If it was just a measurement problem, the car would still work.I'm going to assume that despite how shitty Hydra is, it doesn't allow for any sort of wideband-based fueling correction under real load.

My money is on the fuel filter, and then the pump.

 

Ah yeah mb, forgot that he said it actually fell on its face and wasn't just showing that it was going lean. Hopefully the pump and filter fixes it!

 

You said it's felt like Boost cut. Fuel pumps don't feel like a boost cut when they fail. The boost cut stutters. Description sounds like ignition, including going lean. Could be either though.

My DW is a 2012-ish and is still going.

 

Is there a good way to visualize a misfire on a datalog, six? Or, does it just feel like it hits spark cut when you're overboosting?

 

I don't know if there is, other than going lean and stuttering in boost. Try gapping the plugs down slightly and see if it moves the problem up the boost gauge any.

What coils are you using?

 

The Hydra has LTT where it will add or remove fuel to hit AFR targets but I have that disabled because it doesnt work well, lol. It also has knock correction where it will pull timing and add fuel which I do have enabled. I have a temp correction table and Ive got the fuel map dialed to the point where no matter the weather it will consistantly hit 11.0-11.5 under boost and its been great honestly. I have the wideband for the Hydra and for my AFR gauge and they both show the car going lean unfortunately. Honestly as much as people bag on the Hydra I have found it to be pretty good, the 2.5 software blows donkey ********* but it works.

Walbro will be here tomorrow along with an OEM filter so I will know soon enough.

 

Well I was driving my favorite back roads and went to hit it in 4th and noticed the exhaust note was choppy. Like it was pulling but it was unhappy. Checked the AFR and noticed it going lean under boost. Turned the boost down and did another pull and this time it went super lean and that time it felt like boost cut because it went so lean 16 + AFR that the engine felt like it hit fuel cut. Coils are still the stock NB coils which I realize are known to suck and go bad. The reason why I think its not the ignition is I can go part throttle on the highway, say 5th gear....from 3500 and then watch the AFR just start to slowly lean out as the RPM rises.

 

Plugs are gapped down already @ .022. Yes before the car totally fell on its face the car was still pulling but stuttering as you describe it. The next pull I did it went much more lean and thats when it totally hated life and cut out. I think the pump is failing at an alarmingly fast rate. I really hope its the pump and not something else I have to diag....lol

 

Wouldn't spark blowout result in a rich condition due to unburnt fuel?

 

Oxygen sensor, not fuel sensor.

 

Yes.

Rish, combustion uses up oxygen. If the oxygen is still there because it has not been burned then the gauge will read lean.

 

I guess I expected that it would be more of a misfire than something that resulted in a total lack of spark!

But yes, that makes sense. I had it backwards haha.

 

Verdict : the dw200 is a POS. Dropped in the walbro and it's back to running like a good girl. Thew in a new filter too, but the old one was not clogged at all. So honestly I can not recommend a dw pump. I've never had a pump fail so quickly. It is more quiet than the walbro but that's about the old good thing I can say about it.

 

Duty cycle is the same with the Walbro vs the DW200 so the pumps ( when working ) appear to supply the same amount of fuel to the engine. I loved how quiet the DW200 was and it was doing great up until it wasnt. I feel bad because I told two friends ( one going 2554R and the other going mp62 ) to get the DW200 and they already have the pumps and are installing them. I hope they have better luck than I did.

 

My DW100 did not last long at all. The DW200 takes a long time to prime, but otherwise works fine. About 1 year of use so far. Return style conversion.

Re: duty cycles (presuming you mean injector DC), that is more your FPR than pump, unless you make an extreme change in pump size.