I am posting this here, because more people with F/I knowledge are in this section then in the xB section.

I installed a ZPI turbo kit, one of the prototypes in fact in my driveway. You can check out that install here (56K warning)
https://www.scionlife.com/forums/viewtopic.php?t=172073

Currently the system is up and running. It contains the following items.
330cc tC injectors, Mitsu 14b turbo, 12v turbo pump, oil regulator, greddy emanage blue, and all the normal things.

The problems I am having are When I first start up, it billows smoke for the first few times I boost. ( this past weekend I tightened up a few oil hoses and dumped oil from all the IC piping and changed to Royal Purple 10w30. )

When I boost, it hits up to the .4 bar spring then makes a loud hissing noise (I am assuming this is excessive pressure dump off while accellerating) Most of the times it happens when I try to go WOT.

The car continues to throw DTC P0172 Condition excessive rich every day (I have a code checker at work) It does smell rich in the exhaust.

The car has a bad idle surging problem It will drop to near stalling levels then jump back up to 1000-1200 rpms. When I removed most the system this weekend, I checked all lines and piping for signs of a leak but could not find any (my IC to turbo pipe was a lil loose so I tightened that down) Watching the boost gauge the Vac goes from 20Vac up to 15 and then back down. This happens the most once the car and turbo have warmed up.

Kenny over at Zero Point told me to get ahold of this guy named Chad Block up in York, PA, but he is a hard man to get a hold of. I hope to get up there to get the system tuned but I've been busy and so has he. I have an A/F meter coming this week and I will also hopefully have an emanage support tool built this weekend so I can get more definate results and data.

Any suggestions or info the tC community has would be appreciated. This has been driving me nuts. I think I am driving Kenny nuts too.

 

Well number 1. Sounds like blown seals in the turbo causing oil to build up when you shut the car off. Which in turn burns off when you start it back up.

number 2. the hissing noise sounds normal to me. Just the turbo spinning at high rpm's.

number 3. could be just a code from running rich. Do you have a o2 extender for your 2nd o2 sensor? Thats what us tC guys use to get rid of that. Not sure if the xB uses the same sensors, I would think so though.

number 4. isnt a tuning issue. Emanage Blue only controls WOT tuning. For some reason your stock ECU doesnt like what its got. You say your boost gauge is reading funny. Could be as simple as the vac line to the Boost gauge being alittle lose. I was driving down the highway the other day and my boost gauge line popped off......car died in the streets. Put it back on put a good Zip tie on it and good to go.

 

Sorry bro, you don't even want to know what I think.

 

I have a feeling I blew out the O-Rings on the Turbo. No biggie $18 in parts and a sunday afternoon in time to repair. I have already rebuilt the turbo once checking for distroyed seals.

The vacuum lines are all tight fitting. Infact they are on so tight, they are a pain in the ___ to get off.

The Cat has been relocated from its previous location to after the turbo. From my understanding, since there is a vacuum leak, the Mass air doesnt see the air it is expecting and thus produces the gas to match air thats not there creating a rich condition.

There is two noises, a high speed ticking sound coming from the underside. (recent) and the other is coming from the passenger side, so I am assuming it is the atmospheric dump of the wastegate.

 

So this is the 2nd time you've taken off/rebuilt the turbo in 4 weeks? You have a lot more important problems than a vacuum issue!

 

The vacuum is just one problem. Then there is the oil issue. Orginially when I installed this setup, the turbo was blowin back oil bad, like constant smoking. Took apart the turbo to examing the seals, it turned out to be a hairline crack in the oil pump housing was not allowing the pump to function properly. This has been an on going issue, infact I wish I could have it set up the tC way and tapped into my oil pan, but that is imposible to do. This past weekend I took the system apart to clean it out, check for leaks and dump oil. I dumped a lot of oil out of everywhere, and a lot was left in the turbo/ oil return line when i disconnected that.

 

idle surging is common on the tc's, and i would assume the xb's would be also. mine jumps from 550 to 700 rpms. dont worry about that.

a little oil in the ic piping its not bad, but if your dumping oil out you have definitely blow seals and need to rebuild/replace your turbo before its your motor your replacing.

the sound your hearing could either be the turbo spooling high or the wastegate has a leak and your hearing it.

excessive rich code is fine. you must be running emanage. emanage is lying to your car telling it its running lean so your car will correct with the dumping of fuel. thats normal. as far as smelling rich originally my car smelled rich and it was the opposite, it was running dangerously lean.

 

Bring your car up on June 2nd to CBRD open house. You may have your best chance to get tuned.

 

Well I think I found the source of one problem. I had a nasty buzzing sound going on that I thought was the turbo. I was driving down the road and I hear a ping and then a pop and my exhaust got really loud, so I tripped thinking my turbo blew since I couldn't produce boost. So I limp back to my girls house and look under and discover that the spare o2 bung plug that I had put in had apparently worked loose and fell out. causing a lack of backpressure plus having a quarter size hole in my exhaust. So today I went by advance auto parts and the manager knew exactly what I was looking for since he was a hot rod guy, found me a plug for it, a Doorman Part # 65220 - Oil Drain Plug. Put that in, and its running like a champ, still blows smoke, but I think I need to replace some o-rings. I will check to see if it surges as much tomorrow since it was highway all the way home.

zer0 I would love to go up to the CBRD open house, except that I work on Saturdays.