I'm stumped! 09 M8 Boonbocker PGT Issues...

[summithd]

4th season running this setup. Nothing has changed from last season other than putting on the 2010-011 HO head and putting in the BD 3-degree timing module - THEN taking out the timing module and removing the head to keep the setup the same as previous years for troubleshooting purposes.

Details of issue:

As I increase in elevation from about 5,000-10,500 I have to decrease both the low and mid PSI settings to roughly 0 and 4 to keep the sled from loading up. All other settings stay the same. The sled runs almost perfect at my house (5000ft) with the PSI settings at 23, 32, 43. For the last three seasons the settings I ran were 23, 32, 43 for the PSI range. At this point I am required to configure the PSI settings to 0, 4, 43 to get it to run with very minimal loading up at higher elevations...with theses settings it runs almost spot on - like it has the previous years. One cylinder (random) will load up to the point of not functioning when the settings are near the BD recommended settings for PSI.

- Fuel Regulator: CHECKED - PASS
- 45-46 psi constant
- Swapped with another regulator: 45 psi constant
- Checked boost reference hose for tight connection to regulator and firewall adapter
- M8 spec is 42.8-47.3 psi

- Reeds: CHECKED - PASS
- Changed to M1000 Reeds (have ran these before)
- Reed cages checked out good
- Reeds seal to cages firmly at all points
- Stoppers are in spec

- ECU: CHECKED - PASS
- Swapped w/ another ECU
- Barometric tube is clear

- Injectors: CHECKED - PASS
- Swapped w/ eachother - made no difference
- Checked w/ 9volt battery. Open and close immediately upon applying power
- Checked w/ multimeter - ohms is within spec

- Wiring and grounds: CHECKED - PASS

- Boost hoses: CHECKED - PASS
- All hoses were inspected for leaks
- All connection points were inspected

- Clutching: CHECKED - PASS
- Primary: new sping, rollers are fine, weights are fine, less than 200 miles on clutch
- Secondary: new spring, new rollers
- Belt: Newer belt, deflection is set correctly

- Maunel Boost Controller: CHECKED - PASS
- Took apart and cleaned and inspected

- Boondocker Control Box:
- Fuel settings 3000 (-3, -4, -5)
- Fuel settings 5000 (-5, -4, -6)
- Fuel settings PSI (23, 32, 43)
- Fuel settings PSI NEW (0, 4, 43)
- Swapped w/ another

- Sparkplugs: CHECKED - PASS
- Checked for spark on all plugs
- Changed spark plugs and set correct gap - several times

- Power Valves: CHECKED - PASS
- Cleaned valves and ports
- Checked cable length per spec
- Checked servo motor

- New gas (91) has been used on the six times I've been out this season
- Boost has been turned all the way down during all rides

The only thing I haven't checked is the Ashcroft boost sensor (?) that I believe sends the boost signal to the BD box?? (I'm no expert!)

Any ideas on what could possibly be the problem?? I am stumped!!

Thanks for taking the time to review this post! (I'll probably give BD a call this week)

 

[WyoBoy1000]

Don't really know the functions of the kit that well but it sounds like it is pretty much loading up, which means over fuel or not enough spark.
guesses but may or not be likely
Plugged baro tube,
Sticking injector,
failing pipe sensor,
failing coolant sensor,
failing air temp sensor,
plug wires,
plug caps,
stator,
coils,

 

[summithd]

Just spoke with Jared at Boondockers - he indicated that it is most likely a boost leak. Recommended pressurizing the system and trying to find the leak.

 

[wasatchcomm]

i was thinking it could be that as well
check your throttle body boots and silicone joints, i have heard it is easiest to do this with a can of starting fluid with the sled idling, start spraying the fluid in the spots it could be leaking from, if the engine does not idle up and remains constant after this process most likely its not a boost leak.

good luck

 

[summithd]

Pressure checked the system. Severely cracked Y-pipe on the underside in the welds and a couple other notable boost leaks. All good now...rips as usual.

Thanks for the thread responses and thanks to Jared at Boondocker for promptly assisting me!

 

[Dogmeat]

Pressure checked the system. Severely cracked Y-pipe on the underside in the welds and a couple other notable boost leaks. All good now...rips as usual.

Thanks for the thread responses and thanks to Jared at Boondocker for promptly assisting me!

Ahhhh I should have said something!

Mine did that same last year due to a cracked y-pipe, had it tacked back together and it was fine.

FYI, I replaced the stocker with a D&D and it appears to be running pretty well so far.