So, yesterday I started my putting in an HO intake that I bought from Lenko... install went semi smoothly, stripped some threads... fixed them all, everything is nice and tight... go to start it up... runs really rough @ 3500RPM for a few seconds and starts accelerating too 5000RPM where I kill it... I've gone over the damn thing for the past day, making sure everything is tight, replaced the IAC and TPS... still got the nasty 5000RPM idle.

Everything is as it should be including the TB butteryfly (first thing I checked) and I've gone over the swap guide at quad4forums a few times and right now the only thing I can think of is that gaskets are @!#$ since I just used the ones good ol' Lenko included so I've ordered new gaskets so I'll get to walk down to the parts store tommorow and pick those up.

Anyone else have any ideas? This has me stumped.

Hmm,

Yes check the gaskets.
How good is the port match?

As for your MAP sensor,
R u using your 2.4L or the 2.3L plunger type?

I tryed to use an older 2.3L plunger type, and one start up, the thing actually extended all the way out of the sensor and was sitting on my throttle body plate.

Would be nice if you or Lenko could provide pics.
Mr. Lenko and your -2-1 header.


-M


Remember....syringes go in the RED waste basket.

I'm using all 2.4 sensors and a 2.4 TB... port match was pretty good, needed some more blending but I'll save all the big time work for my other HO manifold

here's the only pic i've taken:

So you're using all 2.4L stuff
Thats cool.

Did you block off the vacuum ports on your TB?

Remember, the FPR is going to the manifold on the far left. So you have to get a grommet or something to block off the port on the TB.

Trying to think as I type, can't remember if there was this the one FPR port or that and another on the TB that has to get covered up.
I think just that.

-M


Remember....syringes go in the RED waste basket.

the FPR (whats on the fuel rail right?) is actually going to a port on the TB... i just have one of the spare ends with a screw in it in the leftmost port on the manifold.

there's gotta be a big ass leak unless the IAC can open the butterfly, I'm guessing alot of air is needed to support 5000RPM.

do you have the opening on the back of the manifold ( under the runners ) plugged

yup... I didnt do anything with the one hole in the head... I remember reading about.... not sure what I should do with it.

You're using a 2.4L TB, right? How do you have it clocked on the manifold??

When I first installed it on my car, I had it clocked wrong, and there was actually an opening on the face of the HO manifold (where there was a space, left by the shape of the TB)... no need for a throttle plate, ha ha, cuz the stupid thing was wide open... air rushed in... 3500 rpm idle.

I turned it 90 degrees and all was well.




<a href="http://www.lenkorules.com/"><img src="http://s93165229.onlinehome.us/images/zm/sig/LRDCsig3.jpg"></a>

JOHN YOU RULE!!! I think I noticed that, didnt really think anything of it.

The throttle lever thing is between the TB + fan/rad... vacuum ports + IAC are on the bottom, TPS is on the side nearest the engine... how'd you set that up?

Ah yeah... turn it 180 degrees. Should fix yer problem




<a href="http://www.lenkorules.com/"><img src="http://s93165229.onlinehome.us/images/zm/sig/LRDCsig3.jpg"></a>

the vacuum ports should be facing up not down , as your pic shows

IT RUNS! Still got a 2000 rpm idle, but that should go away once the IAC resets (only let it run for 5 or so minutes)

IAC never reset, its got a beautiful hissing vacuum leak... at least its semi driveable for the moment.

Take another pic of the set up, maybe we can still help ya?

Also,
Make sure you really have those head bolts tights and everything secure.
Don't go by the recommended torque specs (don't break the bolts either but...) because you'll think you're there but in actuallity there is space.

-M


Remember....syringes go in the RED waste basket.

ok to reset the IAC , turn the key (do not start) count to 15 , then turn key off for 15 , then key for 15 , then key off for 15 , then key on for 15 then start it

that should reset the IAC and put the idle back to normal

Well, still battling idle issues... got the major vacuum leak where the TB bolts to the manifold fixed i think...

Today I added studs instead of bolts for the TB flange, used gasket in a tube crap (my gaskets werent in when I went to lordco), added a k&n breather (@!#$ the ozone), and some vacuum caps instead of a piece of vacuum line with a bolt shoved in the end.

Some more pics:

Oops, typo'ed image URL...

yes that is how the tb should look. when I did mine i didnt have to mess with the idle or anything, so im no help but good luck



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Still leaking?
R u using a 2.3L gasket (or 2) on the ports on the manifold before you bolted it to the head?
The 2.3L gasket kit comes with the manifold and TB gasket at Autozone for like $6.

Those the only places I can think you have leaks.

You're close man,

-M


Remember....syringes go in the RED waste basket.

Its still idling at 1500rpm... down from 1800rpm when I last touched it fixing a major leak on the TB flange (it was hissing) I cant find anymore leaks, and I'm using 2.3L gaskets...

Maybe the IAC takes longer to reset? I was talking to a guy at a show & shine on Sunday, who experienced the same thing... it took a few weeks for the idle to come down to normal when he bolted on a bored out TB to his gm supercharged 2000.

Otherwise, it runs fine... very smooth and goes like a raped ape above 4500rpm.

did you try the relearn procedure i listed above ??

yeah i did, I need to try it again now that I think everything is tight and not leaking... also going to disconnect the battery for a couple hours, see if that helps

thanks for all your help! lets hope when I bolt up a 62mm TB it wont cause me this much grief all over again

No,
But you may get a whistling sound coming off the tb.
Just something the larger diameter TBs do.

Both 59mm Ive had dont it.
Even Events 56mm TB does it.

Good luck bud
-M


Remember....syringes go in the RED waste basket.

So if i did this swap i need a gasket that fits the new HO mani right.

just use 2 2.3 manifold gaskets.

the 2.4's gasket is made out of plastic. so just run to napa and get some good gaskets.


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