Sputtering and rough running with new intake - LotusTalk

TekZones · 08-22-2006, 01:36 PM

Well the subject line says it all, almost. Installed a TurboXS intake and all was well until yesterday (or at least that is when I noticed it). Today it is even worse.
New 2006 Exige, 1750 miles so far in 2 months, all stock except intake. So far 500 miles on intake. No MIL coming on.

Problems:
Very rough idle almost stalling at times (sometimes nice and smooth)
Surging and hesitation when trying to hold steady speed (especially in the 3000-4000 rpm).
Engine temp warms to 200 when moving below 35 and at stops. I know 200 is still very safe but up to this problem, it was steady at 189-192 even in traffic on 100 degree days.
Radiator fan does not come on high (even when I turn the AC on which is supposed to kick in the fast speed of the rad fan).

What I have checked so far:
Fuses for radiator fan are both good.
Have done the ECU reset from another thread, I think I did it right, but no MIL indication letting me know. I went for a drive and still get the problem and high temps.

If necessary I will remove the intake and go back to to to tooooooo stock. I really like the sound and the smoother throttle response that I had until a couple of days ago.

If anyone has any ideas of what might cause these issues speak out.

Thanks, Robert

nugg_dawg · 08-22-2006, 05:59 PM

Bump

Someone help him out.

John

TekZones · 08-22-2006, 06:05 PM

Thanks John, I see that many have read this but.....

qball · 08-22-2006, 06:12 PM

1. Recheck connections (silocone coupler to intake) It could appear connected on top, but be loose on the bottom side of the throttle body.
2. air flow sensor may have some junk on it. Do not touch or clean. Use either MAF sensor cleaner (special product) or go to Toyota dealer and replace with new unit. About $35 if I recall.
3. Did you plug the hole in the throttle body with the little rubber nipple? Check to make sure it hasn't fallen off.
4. Start the car and let it idle (from cold) for about 15 minutes. Then take for a drive. Let idle for 5-10 minutes at end of drive (when warm)
5. Check battery connections

Stephen · 08-22-2006, 06:15 PM

There are 2 black hoses that you take off when doing a CAI; did your kit come with plugs for these; if so, are the plugs still in place? Check all of your connections, make sure everthing is on straight and tight. Check the MAF, is the O-ring on correctly and is it a tight seal? Check if the MAF has oil on it from the filter element, sometimes they have too much oil. If it does, clean it with some air intake cleaner from your local autoparts store. If none of this works, go back to stock and see what happens. Reread the install directions and go through everything again.

Finally, maybe it has nothing to do with your new intake.

Hope this helps.

TekZones · 08-22-2006, 06:16 PM

Thanks qball,

1. Very tight and no movement or sound of leakage when running.
2. Will check after work tomorrow.
3. Nipple plugged.
4. Will do in the morning as it is my daily driver.
5. Connections are tight and no sign of leaking acid.

qball · 08-22-2006, 06:18 PM

Yes... check condition of o-ring. Temove MAF sensor and reset.

Make sure nothing else was knocked loose in engine compartment?

Otherwise, I have no idea?

no CEL, right? Hmmmmmmmmm

dakotan50sw · 08-22-2006, 06:28 PM

sound's like ecu is reading lean esp when you stated temp is climbing to a new high. I fly a lot and one of the thing's we do is lean the mixture at altitude. When we decend we must adjust the mixture making it rich so as to reduce engine temp otherwise damage engine etc. Therefore rich mixture to a degree cool's engine, too lean a mixture increases the temp. Ecu may not have enough time to adjust itself. engine therefore lean. If this would go on long enough CEL would prob. triggor.
When you think about it you have increased the amt of air going into the engine,you have not inc. amt of air going out of the engine, you have not flashed ecu memory to chge factory spec. From what i,ve read the elise has a self learning ecu that will take approx 300 miles to re-adjust itself. This is one of the reson's many have been disappointed by modification's done to the car wihout a Memory flash change. If it's a 06 car you might attempt to teach ecu a bit quicker by turning the car on, but do not start it. with the the ignition on, but the car not running depress the gas peddle to the floor 5 time's . Then on the 6th time fire the car up and see if the Ecu readjusted. Saw this on another site where indiv. were having prob with idle etc on newly fitted intake's. I have decided to not modify my 06 until ECU flashes etc are solid with no Cel prob.etc.

Randy Chase · 08-22-2006, 06:37 PM

Check for an intake leak. Maybe a crack in the pipe.

TekZones · 08-22-2006, 06:46 PM

Well I went ahead and checked the MAF and it was as clean as when new (when I installed the intake). Also checked the throttle body and other intake parts and they are clean and dry. Only one vacum line was left and it is plugged with the provided nipple. The o-ring on the MAF is in perfect shape is seated properly. Yep, there has not been any CEL at all. Will try another reset in the morning and drive to work.

Thanks for the suggestions. If all else fails, retrun to stock and save money for the SC.

TekZones · 08-23-2006, 04:35 PM

Well an update. After I reset the ECU last night, I decided not to drive it to work (just in case) and drove my Jeep instead. And yes, I did feel guilty leaving her in the garage. When I got home I said to myself, self, lets go for another ride to make sure I want to remove the intake. Got her started and let her get warm enough to register on the temp. Went for a combination drive with some highway type of steady pace in the gas mizer gear to keep the rpms from 3-4k; then of course the obligitory curves and runs in the second cam. Overall about 25 miles. I was on half a tank when I started and I added half a bottle of a fuel additive to get rid of any water in the system, since there is a possibility of 'bad' gas. Well the hesitation and surging seams to have gone away. She responded as she did when I put the intake on in the begining. Now I will keep close attention when any of the syptoms happen. It is likely that it was only an ECU learning issue causing the car to run lean but since there was no MIL showing I am still not 100% sure.

Now the question of the radiator fan kicking in on fast or high when the AC is turned on. I forgot to pay attention to that one this evening and will see what happens tomorrow. The running temp today peaked at 191 and mostly stayed from 189-190.

Thanks for all of the suggestions. Robert

Stephen · 08-23-2006, 07:21 PM

Good to hear, hopefully it will run fine from now on. I'm sure you put in preimium gas (at least 91 octane), but I also recommend gas from one of the major companies; I personally only use Chevron. I would not recommend putting in gas from 7-Eleven or Sam's club to save a few pennies.

Enjoy!

08-22-2006, 01:36 PM	#1 (permalink)
TekZones TekZones Join Date: Jul 2006 Location: Sanford, NC Posts: 146	Sputtering and rough running with new intake Well the subject line says it all, almost. Installed a TurboXS intake and all was well until yesterday (or at least that is when I noticed it). Today it is even worse. New 2006 Exige, 1750 miles so far in 2 months, all stock except intake. So far 500 miles on intake. No MIL coming on. Problems: Very rough idle almost stalling at times (sometimes nice and smooth) Surging and hesitation when trying to hold steady speed (especially in the 3000-4000 rpm). Engine temp warms to 200 when moving below 35 and at stops. I know 200 is still very safe but up to this problem, it was steady at 189-192 even in traffic on 100 degree days. Radiator fan does not come on high (even when I turn the AC on which is supposed to kick in the fast speed of the rad fan). What I have checked so far: Fuses for radiator fan are both good. Have done the ECU reset from another thread, I think I did it right, but no MIL indication letting me know. I went for a drive and still get the problem and high temps. If necessary I will remove the intake and go back to to to tooooooo stock. I really like the sound and the smoother throttle response that I had until a couple of days ago. If anyone has any ideas of what might cause these issues speak out. Thanks, Robert Last edited by TekZones : 08-22-2006 at 03:50 PM.

08-22-2006, 06:37 PM	#9 (permalink)
Randy Chase Registered User Join Date: Apr 2002 Location: San Diego Posts: 28,282 Images: 761	Check for an intake leak. Maybe a crack in the pipe. __________________ Please do not PM me. My box is full. Thanks.

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08-22-2006, 05:59 PM	#2 (permalink)
nugg_dawg Registered User Join Date: May 2006 Location: Baltimore Posts: 939 Images: 1	Bump Someone help him out. John

08-22-2006, 06:05 PM	#3 (permalink)
TekZones TekZones Join Date: Jul 2006 Location: Sanford, NC Posts: 146	Thanks John, I see that many have read this but.....

08-22-2006, 06:12 PM	#4 (permalink)
qball Wizard of Pugz! Join Date: Feb 2004 Location: Orlando, FL Posts: 4,575 Images: 3	1. Recheck connections (silocone coupler to intake) It could appear connected on top, but be loose on the bottom side of the throttle body. 2. air flow sensor may have some junk on it. Do not touch or clean. Use either MAF sensor cleaner (special product) or go to Toyota dealer and replace with new unit. About $35 if I recall. 3. Did you plug the hole in the throttle body with the little rubber nipple? Check to make sure it hasn't fallen off. 4. Start the car and let it idle (from cold) for about 15 minutes. Then take for a drive. Let idle for 5-10 minutes at end of drive (when warm) 5. Check battery connections

08-22-2006, 06:15 PM	#5 (permalink)
Stephen Waiting for next Lotus... Join Date: Jul 2005 Location: West of Mississippi Posts: 1,892	There are 2 black hoses that you take off when doing a CAI; did your kit come with plugs for these; if so, are the plugs still in place? Check all of your connections, make sure everthing is on straight and tight. Check the MAF, is the O-ring on correctly and is it a tight seal? Check if the MAF has oil on it from the filter element, sometimes they have too much oil. If it does, clean it with some air intake cleaner from your local autoparts store. If none of this works, go back to stock and see what happens. Reread the install directions and go through everything again. Finally, maybe it has nothing to do with your new intake. Hope this helps.

08-22-2006, 06:16 PM	#6 (permalink)
TekZones TekZones Join Date: Jul 2006 Location: Sanford, NC Posts: 146	Thanks qball, 1. Very tight and no movement or sound of leakage when running. 2. Will check after work tomorrow. 3. Nipple plugged. 4. Will do in the morning as it is my daily driver. 5. Connections are tight and no sign of leaking acid.

08-22-2006, 06:18 PM	#7 (permalink)
qball Wizard of Pugz! Join Date: Feb 2004 Location: Orlando, FL Posts: 4,575 Images: 3	Yes... check condition of o-ring. Temove MAF sensor and reset. Make sure nothing else was knocked loose in engine compartment? Otherwise, I have no idea? no CEL, right? Hmmmmmmmmm

08-22-2006, 06:28 PM	#8 (permalink)
dakotan50sw Registered User Join Date: May 2006 Location: fort morgan, Co Posts: 228 Images: 2	sound's like ecu is reading lean esp when you stated temp is climbing to a new high. I fly a lot and one of the thing's we do is lean the mixture at altitude. When we decend we must adjust the mixture making it rich so as to reduce engine temp otherwise damage engine etc. Therefore rich mixture to a degree cool's engine, too lean a mixture increases the temp. Ecu may not have enough time to adjust itself. engine therefore lean. If this would go on long enough CEL would prob. triggor. When you think about it you have increased the amt of air going into the engine,you have not inc. amt of air going out of the engine, you have not flashed ecu memory to chge factory spec. From what i,ve read the elise has a self learning ecu that will take approx 300 miles to re-adjust itself. This is one of the reson's many have been disappointed by modification's done to the car wihout a Memory flash change. If it's a 06 car you might attempt to teach ecu a bit quicker by turning the car on, but do not start it. with the the ignition on, but the car not running depress the gas peddle to the floor 5 time's . Then on the 6th time fire the car up and see if the Ecu readjusted. Saw this on another site where indiv. were having prob with idle etc on newly fitted intake's. I have decided to not modify my 06 until ECU flashes etc are solid with no Cel prob.etc.

08-22-2006, 06:46 PM	#10 (permalink)
TekZones TekZones Join Date: Jul 2006 Location: Sanford, NC Posts: 146	Well I went ahead and checked the MAF and it was as clean as when new (when I installed the intake). Also checked the throttle body and other intake parts and they are clean and dry. Only one vacum line was left and it is plugged with the provided nipple. The o-ring on the MAF is in perfect shape is seated properly. Yep, there has not been any CEL at all. Will try another reset in the morning and drive to work. Thanks for the suggestions. If all else fails, retrun to stock and save money for the SC.

08-23-2006, 04:35 PM	#11 (permalink)
TekZones TekZones Join Date: Jul 2006 Location: Sanford, NC Posts: 146	Well an update. After I reset the ECU last night, I decided not to drive it to work (just in case) and drove my Jeep instead. And yes, I did feel guilty leaving her in the garage. When I got home I said to myself, self, lets go for another ride to make sure I want to remove the intake. Got her started and let her get warm enough to register on the temp. Went for a combination drive with some highway type of steady pace in the gas mizer gear to keep the rpms from 3-4k; then of course the obligitory curves and runs in the second cam. Overall about 25 miles. I was on half a tank when I started and I added half a bottle of a fuel additive to get rid of any water in the system, since there is a possibility of 'bad' gas. Well the hesitation and surging seams to have gone away. She responded as she did when I put the intake on in the begining. Now I will keep close attention when any of the syptoms happen. It is likely that it was only an ECU learning issue causing the car to run lean but since there was no MIL showing I am still not 100% sure. Now the question of the radiator fan kicking in on fast or high when the AC is turned on. I forgot to pay attention to that one this evening and will see what happens tomorrow. The running temp today peaked at 191 and mostly stayed from 189-190. Thanks for all of the suggestions. Robert

08-23-2006, 07:21 PM	#12 (permalink)
Stephen Waiting for next Lotus... Join Date: Jul 2005 Location: West of Mississippi Posts: 1,892	Good to hear, hopefully it will run fine from now on. I'm sure you put in preimium gas (at least 91 octane), but I also recommend gas from one of the major companies; I personally only use Chevron. I would not recommend putting in gas from 7-Eleven or Sam's club to save a few pennies. Enjoy!

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