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1G Head on 2G block Running Problems!!!

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strippedlug

15+ Year Contributor
52
0
Jun 10, 2006
Salisbury, Maryland
I hope I posted this in the right forum, I couldn't find a better place:
This is what I have: I saved this 95 Talon AWD TSI from the bone yard after some kid slipped the balance shaft belt and snapped every exhaust valve completely off (I'll send pics another time)
I replaced the pistons, connecting rods with 2G.
1st G replacement parts are as follows:
1G Head
1G Intake Manifold
1G Turbo (why not?)
1G coolant pipe
1G Cam Angle Sensor
2G MAF (is this a problem with the 1G Intake?)
I removed the smashed crank sensor and used the 1G Cam Sensor as described in the detailed instructions on www.roadraceengineering.com/1gcasin2g95-96m2.html
I also used a stripped down vacuum diagram to only include BOV, wastegate, fuel regulator
My issue is this. The car runs, barely at idle with almost no throttle control. It seems to be starving for fuel? If I spray just a bit of intake cleaner in the intake vacuum port, it smooths out, full throttle control, and awesome response. If I pinch the return line of the regulator, it also smooths out and will keep running. I know a MAF issue can duplicate this sort of thing, but with so much 1G and 2G mixed, I don't know what's causing what!
Base Timing is perfect. Plugs and wires are new and haven't fired long enough to tell me a story by looking at them. No CEL, and ECU data looks great. Is the MAF being thrown off by the 1G Intake? Has anyone experienced something like this? I pray I was descriptive enough and didn't confuse my potential savior. I wanted my first post to be a success story, but alas I'll say it...I NEED HELP! This is a prestine DSM inside and out! Wish it'd run as good as it looks... I'll gladly post the fix if I find it!
 
Have you adjusted your biss (base idle set screw) ? On top of throttle body , if you did not know .
 
I have not and here's why. I used the 1G Throttle body with the 1G Intake manifold, but some shadetree at some point jammed an M10 bolt where the set screw is. I haven't messed with it but could choke the guy who did it. Would that really cause the strange lean condition? At least that's what it's acting like. To be safe I will change throttle bodies, but I should mention that I drove the 1G Talon to my work for the swap (the car that had the jerry-rigged screw) and it ran fine. bad tranny though.
 
Okay day two and I've done alot of testing with no results. Here's what I did:
Boost leak test---Embarrassed to say it wouldn't hold pressure for 1 sec.
Fixed Throttle body to manifold gasket leak
Fixed vacuum to port "P" (I think)
Fixed minor PCV hose leak
No better starting or idling, same exact issue. Didn't even make a difference though I'm sure it would've been like riding a bull if driven down the road later on. Better to fix what I know is wrong, even if it doesn't fix my main concern.

2G TPS sensor--I went over RoadRaceEngineering.com instructions for 1G head to 2G block and it mentions specifically to re-use the 2G TPS. I don't know how I missed it but today I installed it, and adjusted it with a feeler guage and multimeter. No difference in starting or idling.

Replaced Autolite part #63 plugs with NGK Iridium plugs: the verdict on the Autolite plugs was both surprising and not surprising at the same time. Black as coal after only 2 hours worth of starting and attempting to diagnose the other night.

So I'm running really RICH instead of my assumed LEAN condition. This is telling me it's definately a sensor, ECU issue since even though I'm running RICH, a quick spray of intake cleaner into the intake ports immediately makes for a beautiful running engine.
This really stumps me and I've run out of things to test.
All I keep thinking about is that damned MAF sensor, but I have found no definitive way of testing for good A/F mixture. And I have NO CEL light. Standard ECU Data using a Snap-On Scanner looks great.

On to the fuel pressure test: An inline fuel pressure test after the filter resulted in 50psi at idle. PERFECT right?

Maybe the black plugs are not due to too much fuel, but not strong enough spark? Installed 1G Coil pack and 1G resistor
NO difference.

Rechecked O2 sensors and connectors and all good.
Also used a "Ground Distribution circuit" diagram to help me figure out if I left any ground wires loose or hanging. I'm going to enclose this diagram tomorrow because it's a great source of information for alot of wiring problems. Tells you what each ground controls,and where it's located.

So this is it. Day two, alot done and no improvements. I'm not going to give up, but even though I diagnose driveability issues for a living, I, as well as my local colleagues, are stumped! WHAT AM I MISSING??? If anyone out there can at least throw some ideas of things to test that I may have missed, it would be great!!!
And again, I can't get an answer on if I need an AFC controller to make use of this 1G 2G swap. It's not mentioned, so I assume not necessary without aftermarket modifications. Thanks again everyone.
Shane
 
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