Turbo Troubleshooting Help!

JCasino

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I just returned from a couple days in Revy that were both cut short due to issues with my sled. Prior to this trip, I had just over 500 trouble free miles on this sled with respect to the motor/turbo. I did have an issue with my overstructure (both front and rear) which was replaced under warranty. Following this warranty work, I did have two rides without issue before heading to Revy.

Day one, hit the 30+km's of trail into Area 51, sled ran fine though I was never much past 1/2 throttle as the trail was pretty whooped out. Did a few climbs above the old cabin and sled seemed fine, just a bit boggy in top end, figure its something to due with the amount of snow covering thee hood/intakes. After a lunch break, hit same hill and sled does a big bog when when I hit it wide open, RPM's drop down to 6000 instantly. Check primary spring, plugs, all the easy on hill stuff, but it does it all the time now whenever I give it some throttle. Turbo is spooling, idles fine, runs great until it needs to be stepped on. Have it set at about 8 lbs at the cabin. Don't feel like having my sled stranded this far from truck so call it a day and head back to town.

Day two, checked all hoses and plugs that I could reasonably get at with hood and panels off, looked for kinks in boost line from intercooler to control box, all looks good. Decided to give it another try into Sale. Again, mostly 50-60% throttle to start so no issue, running good, as snow gets much deeper and start giving it more throttle, issue comes back. I did some testing and reviewed the MAX data on control box. Box is set at about 7 lbs and I seem to be able to build to about 6.4 before bog hits but now I notice that the AUX injectors showing zero fuel on the stats screen. I turned boost up to see if I could get them to show a reading and pin it till bog hits again but box continues to show zero for the AUX and about 70-74 for the stock injectors. Figure there's not much I can do on the hill and call it a trip.


My first thought was that the injectors are pooched but I would think the control box would still be trying to send fuel to them, even if they where plugged and still show a reading on the box. Tonight, I will look over all lines, tubes, cables, connnections, etc. but I have kind of already done this with no success. Where else should I be looking/testing that could have this type of result? My only other thought is that the control box is faulty. Any suggestions appreciated.
 

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Sounds like its not getting fuel to me also.
 

JCasino

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How's the fuel pump and fuel filer?

At 500 miles, I would think the filter is fine. I originally was thinking fuel pump as well but I would assume that the aux injectors would see some fuel, not zero. I'll check both these just to rule them out (how would I check the fuel pump?).
 

JCasino

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No guage but have been thinking about installing one. Now might be a good time I guess.
 

cnelson6

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Check your grounds. Something may have come loose causing a open on your secondaries. Or perhaps you have a crack in your boost reference line that tells the box when to start fueling.
 

JCasino

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So I've spent all morning checking all the lines for cracks, wires, etc. - nothing. Swapped out the control box for a new one at the dealers, same problem, checked fuel pressure - 60 psi at idle, tested injectors with control box test function and they fire and flood the motor. Checked fuel filter by blowing through it and fuel came spilling out the return with little effort but as nothing else seems to be providing any clues, going to swap out filter just to rule it out 100%. All, grounds are good,……pretty stumped right now.
 

JCasino

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Well just because you can blow fuel through the filter don't mean that it's not plugged. Plugged solid. Pumped tank out too and lots junk in there as well. Hard to tell if it's from my jerry cans or from manufacture but I'll be straining all my fuel from now on. Could have been worse.
 

cnelson6

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Did you cut apart the filter? If so you you have any pictures it interests me of what could have possibly plugged it so badly.
 

JCasino

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Did you cut apart the filter? If so you you have any pictures it interests me of what could have possibly plugged it so badly.

yah but forgot to take any pics as I was in a bit of a rush at the time. Left the filter at dealers who is now closed until Tuesday so will probably be in the trash by then. Basically lots of black and sandy sediment.
 
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