Engine Stumbling after Supercharger

I need some technical help.

I was installing a supercharger on a 2TR engine, a Toyota HiLux, but once I finished the installation and started up the car, the car seems to start up normally, but once I put my foot on the pedal, it stumbles and stalls. If I press the accelerator very gently, it will very gradually rev.

I removed the supercharger belt and put everything back to stock, but the problem still persisted.

No piggy backs yet, it is really back to stock.

Can anyone please help?

PS: The HiLux is the Tacoma of the rest of the world.

Thanks,
Ibrahim

 

Could be in limp mode? When ecu detects that something semi-serious is wrong, it enters the limp mode, which means that the engine won't rev beyond a pre-programmed speed, you can't accelerate very fast. The transmission may even stay in one or two gears.

Did you disconnect battery when doing install? Check all lines and cables again, do you have any codes?

 

Is this a supercharger kit that came from Toyota ? If it is , then you need to have the computer reflashed for the supercharger. Once this done, you Hilux will run like it should. Good Luck

 

No, that doesn't sound like what I'm facing. I'm not getting any check engine lights on, no codes are thrown; a diagnostics tool did not give any trouble codes.

The engine does rev, but it will stumble a few times before it does. It will also stumble and stall occasionally when the Supercharger is on. When I took off the SC, the stalling becomes much more frequent, and problem does get worse, which indicates to me that the injectors are maxing out in their fuel injection (too rich). Here's a video that demonstrates what I'm facing:

http://www.youtube.com/watch?v=t_Alcatee3c

Here's a picture of the SC:

No, it is not a Toyota SC; I have a piggy back system in hand, I put it in then took it out for troubleshooting. The piggy back doesn't do anything at idle anyway, and my problem is at idle.

 

Engine could not be getting enough air.

 

Ibrahim, your SC instillation looks very neat and well thought out. Have you rechecked all your pieces you installed, could your MAF sensor be installed backward ? I have seen some installations that overlooked the direction of the MAF and it ran poorly.

Also I have found some information about fuel injectors and the duty cycle for them. http://www.stealth316.com/2-calc-idc.htm
If you know the information about your fuel injectors, you could see if you have reached your limit on their duty cycles and you may have to go with bigger injectors. Good Luck.

 

Disconnect the battery for half an hour, then try again with it rigged up "like stock". The ECM will remember the way you ran it for a while.

Is this something that you rigged up yourself? Or is it some kind of kit you purchased? Haven't heard much about S/C's for 2TR-FE. Most people opt for the $500-for-77 hp option and get the 1GR-FE engine instead of the 2TR-FE... I imagine that blower must have cost you a decent fortune. If they want even more, they usually buy the factory S/C. If you haven't heard of someone ACTUALLY DOING this successfully, you might need to consider the possibility that you're just confusing the hell out of the ECM and that it would need a custom ECM to do this successfully.

Is that a BOV tee'd into the pipe after the S/C? If it is, I would point out that the pipe running to the supply side of the S/C is not connected, so the MAF won't be reading the full air volume running like that. It needs to be connected up, or move the MAF to after the BOV.

And as mentioned, make sure the MAF is in the right way.

 

What are those smaller blue hoses after the MAF? Are they open? Any unmetered air will cause problems upon accel. That is the usual cause for a huge loss of power under accel: Unmetered air.

 

No I checked that, not this one.

No, MAF is the right direction, checked that. It would have stalled immediately, and not after a while.

I have done a SC installation on a HiLux before, and the injectors were adequate. I think they were at their limit, but they were ok.

Disconnect the battery, done that many times.

No, it is a kit from Alpine Developments from South Africa. Latest model.

I have done it on the 2TR before, successfully. Also, URD is doing an excellent kit for the 2TR. The HiLux here in our country doesn't come with the 1GR engine, unfortunately, although it does in some other countries.

Yes, the pipe was out in the picture, but if you look at the video, you'll find it is actually connected. The Bypass valve operates with the vacuum line, and releases excess air back into the unboosted air, after the MAF.

That's an invisible pipe

No, the picture was taken before I put the pipe in.

The MAF is definitely in the correct orientation, and definitely working, because I tried removing the MAF housing while the truck was running, and it immediately caused it to stall, which is what should happen.

Thanks guys for your help.

I have taken the truck to a local shop to test the wiring harness and check everything. They were completely puzzled, and couldn't find the source of the problem. The only thing remaining is the ECU, something might have been blown inside the ECU, which is causing this problem.

I took the ECU out to a specialist, and it is being tested right now. I'll have to buy a replacement, but I'm trying to avoid that, because it is quite expensive, and will be a huge disappointment if the problem turns out to be something else.

 

Damn! ECU is good, I hooked it up to another HiLux and it worked flawlessly.

I don't know what in hell could it be.

The car runs way too rich at startup, that's why it keeps stumbling and stalling, and why it doesn't stumble as often with the Supercharger hooked up (more air, less rich).

Why is it running too rich? What's causing it to do that?

Does anyone think it could be the cam sensor? Any thoughts?

 

Would a cam sensor make it run rich?

Now you've established that the MAF is doing *something*, but is it feeding the right values in? Can you test that MAF on another truck?

Are your fuel injectors working properly? Have you tested the signals being sent to the fuel injectors?

 

The only logical answer is that somethng was overlooked or not installed correctly. You have installed this same SC on another Hilux and had no problem. The ECU is good on your new installation, so you may need to go back to page 1 of your installation instructions and recheck every connecton to see if they are correct and that you have no damaged wires or vacuum hoses.Good Luck.

 

You hooked your ECU up to another Hilux? Did it have the same setup, or was it stock?

 

Good news! Problem solved.

The problem turned out to be caused by the MAF Sensor housing.

I installed the MAF sensor on the factory housing, then attached it to the intake pipe, and voila! The hesitation and stumbling stopped, and the engine started idling smoothly.

It turns out that the bore in the MAF housing that came with the kit is too big, and doesn't improvise for air flow management. So air turbulence was happening around the MAF sensor, causing that terrible phenomena.

To solve the problem, I shrunk the bore of the housing in front of the MAF sensor using a few silicon couplers that were lying around me from previous installations. Here's a picture:



Now the throttle response is almost perfect. I think my solution did not quite perfect the air flow through the MAF, I am planning to buy a replacement MAF housing from a local shop that has provision for air flow management.

No the HiLux did not have a SC, but the ECU is stock, it is not reflashed. I use a piggy back system to manipulate the signals entering the ECU.

The HiLux here does not have the immobilizer in the keys, the keys are just ordinary keys. Good for car thieves, but also means you can just throw in a replacement ECU without worrying about reprogramming the key.

 

i wanna see some vids of the 2tr in action with a s/c!

 

Ok, so my MAF housing solution wasn't perfect, the throttle still struggled a bit. But once I bought a properly designed housing (picture below), the throttle response became excellent. The new housing is 1/2 inch smaller in diameter, has those chambers, or grids, to manage airflow, and has this piece that blocks half the bore for some reason, which they say helps manage airflow some how.

Difficult to capture a video while I'm driving

I'll see if I can when the owner picks it up.

But I can assure you of one thing: it smokes my 4.0L V6 Fortuner. And I got JBA headers, removed two cat converters, and got flow master muffler, while the HiLux exhaust is all bone stock. The Fortuner is the SUV version of the HiLux, much like the 4Runner to the Tacoma.

Here's the most recent picture of the SC, with everything hooked up:


Here's the MAF housing after installation: