So...have tried everything I can think of, but can't shake a lean condition on the car (at idle or WOT). Car actually runs great. Smooth idle, no error codes. Essentially after an ECU reset the car will max out the AF Correction, and then the AFR shows ~20 constantly.
Here is what I have done so far:
1) Replaced the Front O2 sensor with known good OEM sensor (was OEM before)
2) Cleaned MAF (Voltage looked good before, but did it anyway)
3) MAP reading looks good
3) Pre Turbo Leak Test - Ran a smoke test and didn't find anything
4) Post Turbo Leak Test - Same. One really small leak. Corrected, and no change
5) Exhaust Leak Test - Smoke test - No leaks found.
6) Swapped fuel injectors - Put in Cobb 1050's. Map was adjusted to account for change. Had Bosch 900's in it before
One thing...there are times when the car will not start...espcially after its been at temp for awhile. Turns over fine, but nothing. If I work with the throttle while cranking I can get it to start. Doesn't happen all the time, but some. Am assuming this is due to ECU thinking Lean condition (when maybe not actually lean)? Usually after I let it sit, and reset the ECU, it starts immediately. Just mentioning so I don't make it sound like there are no running issues.
Only additional thoughts I had:
1) Spark Plugs - Running NGK Irridium IX's vs OEM. Maybe a seal issue on the plug as well, but you would think smoke test would have shown that.
2) TGV Delete - Tune has compensated for this, although I left the servo's plugged in to avoid error codes. Any way either not truly deleted so ECU not adjusting, or vice veran sa with the servo's plugged in it thinks they are there?
3) Do a 02 Sensor delete and put in Wide Band? Might at least tell me what true AFR is and confirm if I have an issue with ECU\Sensors
So you have a sense for the set up:
Hybrid EJ257 (2.0 Heads) 91 Octane Map right now
2002 WRX ECU
TD05 20G Turbo
Perrin Fuel Rails
Walbro Fuel Pump
Fuel Regulator (Set at 36 pst at Idle w\ Vaccuum)
1050cc Cobb Fuel Injectors
NGK Irridium IX Plugs
PCV Delete
TGV Delete
Zero DB AWIC Kit
Tomei Expreme Exhaust, Up pipe
Mike Everson Stainless with Cat exhaust OEM Front and Rear 02 Sensors installed. No EGT
iWire Harness