Modded Engine Runs Very Poorly Can't Figure It Out!

[DSM AWD TSI]

Ok so my friend bought a 92 TSI AWD a couple months ago. The engine was out of the car because the guy he bought it from was swapping the engine (from a 90 Eclipse GST I think) because he had blown the stock TSI engine. The Eclipse engine had only been in the GST for 5,000 miles after being rebuilt. So, after installing the engine and hooking everything up, then engine runs but very poorly (the guy said that everything was ready to go just drop it in and hook it up, and we have no reason to not believe him). The car has an Apex-i SAFCII, a GM MAF with MAFT, and a Zeitronix ZT-2. The wideband AFR reading stays around 19-21 at idle (probably incorrect because trying to richen it with the SAFCII yielded no results), and the car runs EXTREMELY lopey (it has 272 cams but STILL its very extreme). It stutters when the throttle is pressed and slowly revs up (sputtering the whole time). We've double checked all the wiring for all 3 electronic mods as well as the regular wiring harness connections. The fuel pressure is around 50-60 at idle (adjustable FPR with gauge). We did a Boost Leak Test and it isn't leaking anything major. Sorry for the long description, any suggestions on what to check/test/try would be greatly appreciated!

Mod List:
272 Cams
2g header
Evo III 16g Turbo
1g rods with 2g pistons
Cyclone Intake Manifold
Adjustable FPR with 225 LPH Fuel Pump
3" turboback exhaust with test pipe
GM MAF/MAFT
Apex-i SAFCII
Zeitronix ZT-2
720cc injectors
EGR Blockoff
Greddy Type-s BOV (vented, between MAF and Intercooler (nothing between MAF and TB))
Probably some more I forgot/missed


Once again, sorry for making this so long, my friend isn't too great with computers so manual mod list ...

If you have any questions about the setup or anything just ask and again any input is welcome! Thanks!

 

[tnl]

have you tried to take away some fuel or adjust the fuel pressure regulator? the stock fuel pressure regulator is at 43psi. with a 255lhp and fuel pressure turned up that maybe be way to much fuel. Ive read that its hard to tune with the safc with anything larger than 650cc injectors also. Please note I'm no pro with a fuel setups but this is what i'd start searching and find out where to set your regulator. and look for boost leaks.

 

[Eclipsethis90]

Check your timing, especially the intake cam. I have experienced a jumped intake cam tooth before and had a wicked idle and sputtering as you describe. Just a thought.

 

[Killa_dsm]

Make sure your plug wires are in the correct order. Also what is the S-afc and maf-t set to since it has 720cc's?

 

[blakktalon]

Did you try adjusting the dip switches on the maft? Try checking to make sure it is set for the right injectors and play with the base switch.

 

[1Gdsmdriver]

I agree with blakktalon on checking your dip switches. i think you have your fuel pressure a little high for a 1g so you could possibly be getting poor atomization of the fuel and just food for thought but when i put my maft and afc2 in i set the maft to 0 except for the injector size and used the afc2 to tune. you could try that and see if that helps.

 

[hubz91talontsi]

Im going to assume that one of the gaskets has been destoyed, and that you have a boost leak. Pull your plugs just to make sure your wideband isn't the problem. You could actually be giving it too much fuel.

 

[dsmspickdad]

I would say too much fuel. Try leaning it out with the safc and adjusting the fpr down. Also make sure your maft is set correctly. Also did you reset the fuel trims when installing the maft and safc, by removing the fuse? Are you logging your car so you can adjust the maft?

 

[DSM AWD TSI]

Thanks for the replies! I'm going to try and answer all your questions and note your suggestions (in chronological order):

Like I said we already did a boost leak test and it was pretty good. Going to turn down the fuel pressure and see what happens. The SAFCII can take away 50% of the fuel so 720cc - 50% = 360cc which is less than stock, should be fine?

Will check timing belt/timing marks.

We already checked the plugs but will double check. We checked the MAFT settings against the manual for 720cc injectors in a 1g and everything matched up. The SAFC is set to lean out a lot on the bottom end (We tried taking away fuel from the setting it was on already, instantly got better, we tried adding some fuel and it got a TINY bit better but almost not noticeable).

Checked the MAFT switches and settings.

Checked MAFT switches, going to lower the fuel pressure.

Did a boost leak test. Plugs looked fine (car hasn't ran very long).

Will try to adjust FPR, already tried leaning it, it made it worse. The battery was out of the car so I'm guessing its reset. Once again, the whole setup was already hooked up all we did is pop the engine in (MAFT and SAFC were already tuned to the engine by previous owner).

Thanks guys! Going to try all the stuff I haven't already (and re-try some other stuff too just in case)

 

[chanley talon]

It could be possible that you have a injector hanging open. I think i would send those injectors in somewhere and have them cleaned and checked. To much fuel will for sure cause a mean lope. So if checked all the fuel it must be in the injectors. Heck i got some 550s if you wanna trade.

 

[dsmmikej]

Check your firing order on the plugs, this thread just screams wrong firing order!

 

[jesse_fc3]

Check your firing order on the plugs, this thread just screams wrong firing order!

+++1 or timing

 

[tjbiker031]

+++1 or timing

How do you come up with timing when he just said when adjusts the fuel, it gets better?

 

[DSM AWD TSI]

It turned out to be that the timing was off by a tooth or so (I wasn't there when my friend took the T-belt off, so I'm not sure on exactly how far off it was) and that it was running lean. Fixing the timing got it to run better (well enough so that the wide-band O2 finally started showing non-open air readings) and then we added some fuel (technically told the ECU there was more air so it would send more fuel) and now it runs MUCH better (almost runs perfectly)! Thanks guys!

 

[coryd]

The SAFCII can take away 50% of the fuel so 720cc - 50% = 360cc which is less than stock, should be fine?
QUOTE]

doesnt work like that