Need urgent help - misfired, died, wont start
 

Hello all, this is my first post on here and I'm sorry it's such a long and demanding one.

Car is a year 2000 UK Turbo with 103k and has:
Apparently remapped
FMIC
Yellow injectors
Decat straight through exhaust
Aftermarket air filter.

Last night I was joining a dual carriageway and put my foot down in second, I don't usually redline it but on this occasion it just hit redline and immediately lost all turbo power, the dump valve would no longer dump, all I got was wastegate flutter. The boost gauge had a fit and was fluttering so quickly I could barely see the needle (it was only fluttering over a small measurement, probably a 1-2mm's) I managed to cruise about 3 miles to the next exit in 4th gear, as soon as I slowed it started to die and ended up dumped in a parking space.

When I tried to start it, it just about started up with a bit of throttle, it misfired terribly and stalled. Every time after this it got worse until the point it ended up on 1 cylinder before dying and now won't start at all.

There was no CEL or codes stored, I did an ECU reset via unplugging battery, checked battery terminals, checked all hoses, pipes and connectors by eye/hand and can't find anything obvious. The grounding points seem a little old but are all there. There was and is no oil or coolant leaks anywhere that I can see.

I was thinking fuel pump but I can hear it priming when ignition turned on, it just feels like there's no fuel getting to the engine. I also thought could be a bad spark or a coil pack or maybe MAF but would any of these fail so suddenly and cause these symptoms?

Does anyone have any ideas where to start diagnosing this?

I'm supposed to be at work 60 miles away tomorrow and with it being christmas day I cant even use public transport or get a hire car

Thanks in advance.

You're thinking along the right lines, and it could be any of the things you mention.
The fact that it died as you hit the limiter would lead me in 2 possible directions.

1. Possibly something moved as the engine rocked...... so check the common things, my bet would be that one of the fmic pipes has blown off or split.
So check and double check every join, even the ones you can't see, behind the bumper etc.

2. Lets not go there just yet.

That's what I thought it was at first. When I first fitted the FMIC one of the pipes blew off as it wasnt on tight enough and it felt very similar. When it happened lastnight I thought it'll be fine, It's probably happened again I'll just pull over and re-clamp it, but I have checked them all and they seem to be ok unless I've missed something. I'm not overly familiar with these engines but have a rough idea.

I forgot to say othat since I've owned it it's thrown up MAF and O2 sensor codes, the MAF was cleaned and it seems to run ok but the codes always come back. Could a MAF or O2 sensor failure cause it not to start.

With regards to number 2, I had it checked by a trusted Subaru specialist recently and he did say the cam seals leaking slightly, I had planned for a new timing kit, water pump etc in January. But yea, thanks for not spoiling my christmas just yet :)

QUOTE
I forgot to say othat since I've owned it it's thrown up MAF and O2 sensor codes, the MAF was cleaned and it seems to run ok but the codes always come back. Could a MAF or O2 sensor failure cause it not to start

Not as a rule, usually just causes rough running issues. If the MAF was playing up it should run better with it disconnected, so you could try unplugging the electrical connector and see if it will start.

A couple of other simple things you could check that would tie in with symptoms.
Has the dump valve jammed open?
Is the turbo waste gate closed?

Thanks for your replies.

When the MAF was cleaned I experimented a little first, it would still run when unplugged and didnt stall. Now if I unplug it it makes no difference and still won't start.

I did wonder if the DV is stuck open as there was no noise at all from it immediately after, not the slightest hiss but the wastegate would flutter. Could a stuck DV this cause it not to start?

I'm not sure about the wastegate, how can I tell if it's closed or open? It's very stiff, too still to move just by hand.

If the DVD was stuck open it would give. the same symptoms as if a intercooler pipe had came off. I..e. Unmetered air drawn into the engine. So it may try and start or splutter initially until the ecu detected there was no air passing the MAF.

If the waste gate actuator rod is very stiff, chances are the wastegate is closed as it should be. The only time I've had a waste gate open is when the rod has come adrift. And to be honest even if was open the engine would start fine but you wouldn't create any boost pressure.

Ok well I have a list of things to check, the DV is a piece of cake to get off so I will look at that first. Thanks for your help and I'll report back if I find anything.

Good luck, keep us posted.

Sounds like you have popped a pipe off somewhere or maybe the cam belt timing jumped ( hopefully not that option )

I have a gut feeling that could be it.

I have checked the intercooler pipes at every connection, all other pipes seem ok and the dump valve is definitely closed.

With it being a fmic, there are a fair few joints to check, some cheaper fmic kits, and certain hose clamps, are known for issues, so it may not be anything too serious.

So I have checked a few more things - it's definitely getting a spark,fuel is getting past the fuel filter and to the injectors but did not check if injectors are working. Double checked all intercooler and boost pipes and tried a new battery in case it had died.

I pulled the belt cover back enough to see the belt which is still on and still tight but it's looking increasingly like it's jumped some teeth. Will be getting recovered to the garage once they're open and I'll brace myself.