nobody can figure this out!!

[projectgotsi]

well, ive spent hundreds of dollars at the dealership and dozens of hours under the hood, but I cant for the life of me figure this out. I Have a 93 tsi 5sp with a 90 engine. Car ran fine till the timing belt broke, so I ordered a remanned head from national cylindar head and bolted it on. Car has not run right sence. These are my problems: Car has no power over 4000 rpm, I start to feel boost, then it just sits at 4-5k with the turbo screaming and the car not accelorating. If I SLOWLY press my foot to the floor, it's better, will pull to around 5500 and then thats it. Also, it starts hard....takes several cranks to start..then when it does, it stumbles to a start then idles like a champ at 800 with NO idle surge, skip or anything. The other problem is my gas milage has gone to crap. Used to get over 300miles out of a tank of gas...no i'm lucky to get 200.00 I took the car to the dealership and they put a new waste-gate cillanoid, turbo gasket, "re-routed vacuume hose" and put a new o2 sensor on (cost me 600.00) car ran smoother but it did not fix the prob. Dealer tried to tell me I may have a cracked piston, but I checked when the head was off and all 4 were clean. I also pulled a compression test and pulled 148-150 across the bord. Last thing I did was put a new fuel filter on and nothing...PLEASE HELP, any tips would be awesome. (dealer also checked all vacuume lines and they were all routed and working, they also put a manual boost gauge on the turbo and it puleld 13.8) Thanks, Andy

 

[jott5555]

ok this is from my exp only and it could be off but it sounds a lot like my prolem, when u did the timeing belt you didnt do the tensioner correctly, they did this at a shop doing my timeing belt and they did it incorrectly belt snapped and bent valves, but it ran until the tensioner relaxed (4 mons) and it ran like crap, that could be one problem

the other it could be outta phase, that will give u a wacked viberation and run like crap, check em both,

good luck bro

 

[projectgotsi]

thanks, belt is tight....cam gear "timing marks" all line up. When we put it all together...we tripple checked our work against the haynes repair manual...also turned the engine over like 20 times manualy (wrench on the crank) to make sure everything was good. All markes lined up....

 

[jott5555]

you cn do all that and still have the eng outta phase

heres a link on how to do it
http://www.vfaq.com/mods/timingbelt-1G.html

step 24 but if u did it like that it wont have a problem, but a lot of shops dont do this and causes issues, plus the tensioner but ne way just my 2cents

good luck bro keep updated

 

[mazdamx6pwr.com]

You try a intake presure test for leaks?

Adam

 

[splattj]

I'd be willing to put money on the cam timing being off. 13.8" Hg at idle is way off. You should be around 18" on stock cams. I would guess that you are one tooth off at the crank.

 

[projectgotsi]

thanks for the tips...all the timing marks lined up before I ran the car. The only ones I have checked sice are the cam markes and they still line up. Should I mess the the cam angle sensor (havent touched it sence the head swap...put it in approx the same position it was in on the orignal head) also a few more things I forgot to add. At idle I know the the boost gauge (stock boost gauge) should read -7...but it floats from neg. 5 to close to 0 at idle...the shop told me the gauge was functioning properly. Car idles around 900rpm...if i bring the idle up to like 1200 by pressing the gas...the gauge drops to -7 and then will go up as the idle does. The plugs are also nasty...caboned up. Orignal plugs that came out of the car had like 20k on them and the were decent...my new ones have like 750miles on them and their gone......thanks, Andy