Misfire problem, Bank one Fuel trim

[MOSFETS Forever]

Fellow N54 friends, I would like input and ideas. I'm new to the form and this problem is driving me insane. My car is currently experiencing a mixture control problem on bank 1 ONLY. Under boost stft will go to -32%, even under light acceleration. It is also Throwing corresponding misfire codes for bank one.

Here is what is done to my car:

MSD80, 335xi
Custom Motiv Flex fuel tune from CKI@Motiv
VRSF factory side inlets
AEM LPFP pushing 75 + psi
Duel cone intake
ECS tuning charge pipe and BOV
ECS tuning Oil catch can
Pushing 22 psi under optimal conditions, E60 ish
95k miles
stock turbos
stock Down pipes
Stock inter-cooler
Stock everything else


Here is what I have done:

Changed injectors and replaced seals on injectors with proper tools
Checked injectors for leaks
New NGK spark plugs (I tried .022 and .018 gap)
New Delphi ignition coils
Replaced all Mosfets
Cleaned and inspected intake manifold
Plugged fuel tank vent port on TB
New intake and TB gaskets
Plugged intake ports in valve cover.
New valve cover gasket
Cleaned map sensor
Replaced both upstream oxygen sensors.
Compression check, 180 psi +- 5psi on all cylinders

When the problem started, It was like a switch was flipped and then it ran like crap since.
I have attached data logs using mhd covering this problem for those willing to review them. I've communicated with Chris CKI@Motiv about this, but hes a busy guy.
I'm running out of ideas. I'm going to pull the turbo inlet on bank one and check the turbine, but I have no smoke or water coming out the exhaust.
The car idles fine, but almost makes a sound like it has a huge vacuum leak under any driving condition. Thoughtful input is appreciated

 

[blisstik]

Swap injectors 1/2/3 with 4/5/6. You'll have to recode them but you can see if the trims switch to bank 2

 

[MOSFETS Forever]

Swap injectors 1/2/3 with 4/5/6. You'll have to recode them but you can see if the trims switch to bank 2

I have already done this. I moved bank 1 to bank 2, replaced the entire set, and then moved that set around as well. I also installed new injector seals and decouplers. Injectors were coded with INPA. The problem appears to remain on bank one only.

 

[blisstik]

I'm sure you tried swapping your plugs and coils too. Maybe check the fuel rail for cracks? Also, I would load all your logs to Datazap and link them here. It'll be easier for us to look into them.

Have you tried going back to previous version tune? Turned off burble and all that.

 

[dyezak]

Motiv is one of the best tuners available.

But this is a case study in factoring in your tuner's availability and responsiveness. The best tuner in the world does you no good if they never look at your car.

Not a knock on Motiv...they have limited availability for a reason.

 

[MOSFETS Forever]

Rail pressure is fine. Reads anywhere from 700 psi to 3200 psi. I have not smelled any fuel or seen any leaks.
Spark plugs and ignition coils are all brand new, they don't even have 20 miles on then. Sourced them from FCP Euro. No misfire is noticeably present at idle.

Here are some logs on Datazap.

https://datazap.me/u/mosfets-forever/log-1527515068?log=0&data=3-25

https://datazap.me/u/mosfets-forever/log-1527514967?log=0&data=3-25

https://datazap.me/u/mosfets-forever/log-1527514914?log=0&data=3-25

 

[Cornfed54]

Total shot in the dark, but have you tried filling up with 93 and flashing back to original stock .bin to rule out anything wierd with flex fuel? Otherwise, I’d say significant boost/ vac leak but it seems like you have looked over everything thoroughly to rule that out. Any chance that one or more of the intake mani gaskets are blown/ missing? I’ve seen them cause your same symptoms, hope you get this figured out soon, problems like these can drive a guy nuts.

 

[MOSFETS Forever]

Total shot in the dark, but have you tried filling up with 93 and flashing back to original stock .bin to rule out anything wierd with flex fuel? Otherwise, I’d say significant boost/ vac leak but it seems like you have looked over everything thoroughly to rule that out. Any chance that one or more of the intake mani gaskets are blown/ missing? I’ve seen them cause your same symptoms, hope you get this figured out soon, problems like these can drive a guy nuts.

I'm starting to lean towards a boost leak problem. I pulled the fan out to check the forward turbo (which checked out fine, it almost seemed new) and noticed that the charge pipe going into the intercooler was partially dislodged. I pulled the hose out and didn't see an o-ring to seal the pipe, so I'm going to see if I can find it and match the size for one local, or else I'll order a new one. Probably going to remove the factory intercooler and inspect and clean it. I'll post with updates.

 

[Cornfed54]

That would be great if that’s it, fingers crossed. The only thing that seems odd is that typically both banks would be thrown way off since it’s a full system leak, not at the intake Mani where one or more cyl in a bank could have a leak, causing one bank to be thrown off. Do your trims seem to be business as usual on the other bank? Do you have any old logs to compare by chance? Sorry if you posted them already and I didn’t catch it.

 

[MOSFETS Forever]

So here's an update for those following.

In chasing down a potential boost leak, I removed the intercooler and cleaned the seals and the intercooler itself. I then smoke tested the entire intake system only to find no leak at all.

My thoughts then turned to a possible problem with the MSD 80 computer. They are known to have several weaknesses, I had already replaced the MOSFETS twice. So I got help from Motiv and upgraded to MSD 81 only to have the exact same fault. At this point I was completely stumped. I talked with the guys at Motiv some more and decided that it had to either be a bad turbo or a bad catalytic converter.

Today I dropped the subframe and removed the down pipes. Both of the stock turbos looked clean as a whistle. No signs of wearing out, oil leaks or water leaks. And both turbine shafts feel solid and the waste gates are good as well. Then my inspection turned to the cats... oh those damn cats...

Remember that the fault was a bank one mixture control issue only. Well the cat for bank one no longer exists. The element is literally gone. Not a single trace of it remains. I suspect that the secondary catalytic converter looks like a sand box. I'll have to wait until this weekend to find that out. The bank two cat is still in tact but it is showing signs of wear as well. I just placed an order for the VRSF xi down pipes. I'm just ready to have my car back.

I have never seen a catalytic converter fail like this before. I'll let the picture do the talking.

Flashlight shining from the other side.

Just an empty can.

camera shot with no flash, and a light from the other end.

 

[blisstik]

Might as well get non-catted DPs.

 

[fmorelli]

Ok this begs the question - why did you not get post-cat ODB-II codes? This car should have thrown codes like a Christmas tree.

Filippo

 

[SlowE93]

Ok this begs the question - why did you not get post-cat ODB-II codes? This car should have thrown codes like a Christmas tree.

Filippo

Im going to guess here....custom tune and lambda codes shut down due to MANY people running catless dps to avoid CEL.

Thoughts ?

 

[SlowE93]

Might as well get non-catted DPs.

He is half way there already

 

[MOSFETS Forever]

Ok this begs the question - why did you not get post-cat ODB-II codes? This car should have thrown codes like a Christmas tree.

Filippo

That is a fantastic question. I would also think that I would get a catalyst inefficiency code for bank 1. But I am running the Flex Fuel system from Motiv, and I have a custom tune for the system from Motiv as well. I would guess that they coded out some emissions controls as part of the tune. But no matter, as I have new DP's coming and I ordered the O2 simulators to go with it.

I really just want to remove the secondary catalysts and see how much of the primary is left in there. I'll probably just bypass them for now, but down the road I would like to have some form of high flow cat on the system just to control the un-burnt fuel smell that will come with removing the cats.

I'll post pictures and update when I take the secondaries off.

 

[fmorelli]

That merits a quick email to Chris - I'd want to know if something was coded out as you say.

BTW I'm pleased with my setup - I have the VRSF catless downpipes. I then built my exhaust with hi-flow 49-state CARB cats in the mid-pipe, extended my post-cat 02 sensor loom with Deutsche connectors, and have a Vibrant 02 J bung for the 02 sensors at the mid-pipe. Nothing is coded out on my car, and it runs clean. The mid-pipe cats help tame the exhaust sound as well. By the way the mid pipe cats are not particularly expensive.

Good luck. Hope this solves your issue ...

Filippo

 

[MOSFETS Forever]

Had a chance to cut the secondary catalytic converters off this morning. And as expected I found the bank one primary converter sitting in the secondary converter.

This is your catalytic converter. . .

This is your catalytic converter on drugs.

 

[NoQuarter]

seems problematic

 

[fmorelli]

I doubt that's a problem.

Your issue was not the hole in the first cat but rather the plug up in the second cat. Wow, wonder how common this is?

Filippo

 

[doublespaces]

This is actually pretty interesting. Did you run 2 step at all? Maybe you had some major backfires that caused this.