update: failed NOx and bucking
 

in an attempt to reset the computer, i disconnected the battery for about a minute and then went for a drive.

the boost would go to about 1.6 bar and then the car would start to buck and i could 'popping' noises or something from the rear. there must be something wrong with the boost system. this happened in 1st, 2nd, and 3rd gears.

any ideas?

could be a lack of fuel... check to see if your fuel pump is working right, or if maybe one of you injectors is messed up.

ok, now i am pissed.

one of the hoses at the intake boot is totally rotted. i think this is causing a pretty good vacuum leak, as i can hear a hissing from this general vicinity when it is idling. so i took the tube that exits the intercooler off, along with the BOV, and found a bunch of motor oil and metal shavings in the exit port of the intercooler. gawdammit.

no one has anything to say? not even sympathy? (crying soflty)

The intake boot being rotten is not that surprising on these cars. You'll have to replace it.

Motor oil in the intercooler isn't surprising either, probably accumulated oil vapor from the PCV system. It'd be good to clean out the intercooler if you can, though.

The metal shavings are surprising, however. Usually that means your turbo lost some or all of its compressor wheel. Your sig says you have a new engine. Did your turbo blow before? If so, you or the PO really should have cleaned out the entire intake tract.

-Ian

the intake boot isn't rotten, its just a bunch of the larger vacuum hoses coming off of the boot. the boot and BOV, along with all of the small vacuum lines. actually look brand spanking new. what i can't figure is why they would re-use the other hoses.

i am starting to feel better about the turbo, as it is POSSIBLE that the shavings are from a previous problem and not all of the stuff got removed. i'll just have to pull the hoses on the turbo and check it out.

as for the oil, i may just be paranoid. i've never had a turbo before (this is my third day) and i don't know what a normal amount of oil would look like. there was a small puddle of the stuff in the rubber connecting boot at the intercooler exit port.

usually you can tell if your turbo is shot by removing the inlet boot on the turbo and trying to wiggle the nut in the center of the port. It should have little or no play and make sure everything spins free

see my update to update post :)

Uhmmm turbo cars are quite sensitive to vacuum leaks.

Oil in the pipes is relatively normal. A certain amount of oil will seep through the seal on the compressor side.

I would pull that intercooler out and have it cleaned.

Last thing you want is more metal shavings going into that engine.

update: bucking fixed
 

turns out the DME was bad...

i tested the TPS, the fuel delivery, the fuel pressure, put in a different KLR, checked EVERY vacuum connector, every hose, every electrical connector to do with the electrical system. it was down to faulty injectors, the wastegate (which i really doubted, as it would go into 'safe mode' at random and the boost would only go to 1.2 bar), or the DME. just for grins, i put in a different DME, and it works. just. like. that.

can you say smiles all the way to 110MPH?

Good to hear to found the problem! Home that DME didnt set you back too much.