Hoping somebody can help me out here. Tuner is stumped along with me.
Here's a video of the issue.
View My Video
http://tinypic.com/r/2vi5e6d/8

10:1 2.0 50k on all sensors
Stock 8 turbo
New denso front o2
93 fuel
Fic 2150 (new outta the box)
2 255 walbro (both work well)
Tephra v7
NGK plugs gapped to .24
0 boost leaks

Car will idle and cruise fine, once I get into boost it sputters and won't run. Its fouling plugs pretty quickly. Have replaced them a couple times already.

Fuel pressure is 60 psi (video was taken before 2nd fuek pump was powerd. aem pressure gauge). I just removed fuel filter (eliminate possibility as restriction).
Afrs are good except as soon as I get into boost my afrs near 14.0, they lean out. Injector duty is at or above 100%.

What could it be at this point?

 

Try swapping in a cam angle sensor that you know is in good working order.

 

Try 0.020"

 

Stock turbo should be no where near tapping out 2150 injectors. 100% it is fuel/tune related.

 

Agree. Similar issue here with a change in plugs fixing the matter. Stuck with the stock plugs. Hope that helps. Also IDK where you get your gas but maybe they are selling you some crappy gas.

 

I had same problem a few weeks ago as well, when looking at the plugs visually they looked fine, but I replaced and re-gapped the plugs a little tighter problem solved.

 

I'm waiting on a ride to the parts store I'll try a new cam sensor. Good idea.

And shouldnt 0.024" be alright for the plugs? I just tried 0.020" no difference.

I hear my main fuel pump relay clicking on extremely loud when I hit the gas. Is that something I should be worried about?
I bypassed the relay and it doesn't seem to be acting any different.

But then again the tune is pure crapola right now also I don't know.

 

I was having issues with new plugs and misfires at "high" boost. English suggested I run .020. Runs great, now.

 

I think its more than plug gap.
It can't even boost 1psi before breaking up.
This isn't high boost, its boost in general. The car is literally undriveable with the small 8 turbo on a 2.3

Heres a video. I'll add it to post #1 too.

View My Video
http://tinypic.com/r/2vi5e6d/8

 

Your car doesn't sound right even at idle. Do Compression and Leak Down tests.

 

Car needs a tune. Motor is new. But this break up issue shouldn't be there. It drove fine for the 1500 mile motor break in. It's probably partially because of the tune.

But even the tuner told me its more than the tune. Car is undriveable and he cannot tune it as is. And I have been trying so hard to pinpoint an issue with no luck.

 

im a little confused....

new motor that you have drove around on for 1500 miles... and it ran fine? with no tune and the 2150's?..

or was the motor new with all stock stuff and then you put the injectors in?... and then when you put the injectors in this problem started.

from your general description... i would say the injectors are not scaled correctly and that nasty noise is borderline hydraulic lock because the injectors are dumping so much fuel

 

The first 1500 miles had a decent break in tune. Everything is the same as it was then to now.
Except the 2nd fuel pump was added and that was added by the tuner.

When I took the car back to get the final tune it was acting up like this before I brought it there.

I guess the tuner hasn't put a lot of time into it. But he's convinced the fueling issue has to do with the injectors

 

Checked the cam sensor and there was oil all over it.
I didn't even bother to oht the new sensor in yet and I will tomorrow after I replace that cam seal.

Could oil all over the cam sensor be the cause of the tunning complications?
I talked to the tuner and a little bit of oil in the CAS housing is normal?
Now I'm really lost

 

Since you are on stock turbo, try a stock size set of injectors. Still got your stock resistor pack for stock injectors?