Black Soot and won't run

[CellerDweller]

Well, what I was hoping would go smoothly didn't. I started the motoman break-in method on my rebuilt engine and 6 miles in a heard a "clunk" which sounded like the front passenger side of my engine compartment. At that point I lost all power and drove 6 miles back home limping along at 20 mph. The car was running really good up until that point... Once home, I pulled the plugs and there is black soot on all four as well as the muffler tip.

The car is a 96 Talon AWD TSI with auto transmission - everything stock, bored .020 over with a 3" catback exhaust. The cat is still there along with the stock downpipe until I get my shipment from Punishment Racing. Oh, I also did the BSE during the rebuild. I cleaned and bled all the lifters per VFAQ before re-installing.

I checked the compression which is 160 to 165 psi (cold on all cylinders), since the car back fires and doesn't want to start or run. It was idling when I pulled in the driveway, but it was rough.

Oil pressure was reading good
Engine temperature was normal
Continuity on new plug wires was good
Continuity on both primaries and secondaries of both coil packs was to spec.
tested the transistor pack as per the service manual - both transistors were good.
New BPR6es plugs - checked for firing and all fire.
Timing marks all line up correctly on sprockets and crank.
I hear no mechanical interference with the plugs out (coil pack, transistors, and injectors unplugged).
The engine sounds normal with the plugs in and coils and injectors unplugged, but as soon as I connect the coils, transistors and injectors the engine hammers like the timing is way off.

What am I missing here? The cam angle sensor is new, not OEM, but new. I do not have any way of logging at this point. I'm having a hard time dumping more money into a car that I may be pushing into the woods to rot!

 

[BeeRacer930]

Did you possibly blow off a coupler cause a boost leak would cause you to run rich which from what you said about the plugs you are.

 

[boostront]

^+1...Sounds exactly like you compleately blew an intercooler pipe off.I had the same thing happen to me.Limped it home scratching my head.When i got home i climbed underneath it and the hot pipe to the intercooler wasnt even connected anymore.Deffinently check your pipes.

 

[mattasi]

It does sound like a boost leak, hopefully thats all it is.

 

[CellerDweller]

Going out to check for boost leaks...Thanks for the advice. I'll post what I find.

 

[BeeRacer930]

Any luck?

 

[CellerDweller]

You were spot-on! The hose from the cheap plastic BOV to the intake blew off, but it was off just enough not to initially notice it. I clamped it back on, finished my 20 mile break-in (well, 26 just to make sure) and changed the oil. Everything is running good.

I want to buy a Punishment Racing FMIC - the one that bolts to the bottom of the crash bar, which will get rid of these crappy rubber lines and POS BOV. However, I've owned this car since last October and have only driven it about 2 weeks before blowing the original turbo, then drove it for another two weeks and burned out two exhaust valves. I rebuilt both the top end and bottom end with new parts and have a new EVOIII-16g to install (when I purchase and install the supporting mods of course), but I really want to get some drive time on this car before spending a bunch of cash.

Again...thanks for the advise!