Mazdaspeed Overboost/Boost-cut in 5th and 6th gear

Discussion in 'Mazdaspeed 3 Troubleshooting' started by RC12, Apr 16, 2023.

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  1. RC12

    RC12 Greenie N00B Member

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    Hey there everyone, I have an issue related to a 2007 Mazdaspeed I bought last summer which underwent an engine swap (swapped with a 2013 speed motor) ill get into more detail about it in a minute, however, the main issue I'm looking to resolve would be both codes: P0234 (Turbo/Super Charger Over Boost Condition) & P2188 (System Too Rich at Idle - Bank 1)

    I bought a 2007 Gen 1 w/ 213,000km which had a spun bearing meaning the engine was only able to start and not in a condition to drive upon buying (I didn't have the car inspected because I got it for sub 3k at the time and knew I was going to swap the motor). The engine with the spun rod had a few basic mods (hpfi, cold air intake, and an eBay blowoff valve), none of which concerned me because that engine was essentially useless other than basic parts plus turbo. I do work in the automotive industry and work closely with my local Mazda dealership here in western Canada so I asked the shop foreman if I would be able to swap a 2013 speed 3 motor with 77,000km from the wrecker (the engine was proven to be in healthy condition), which he and the wrecker both said was compatible, so there it begun. The entire engine re and re was done at the dealership over 18 hours of book time, the foreman suggested I put all new seals and gaskets hoses etc. The transmission/clutch was deemed to be in good condition (the previous owner put a Duke stage 2 clutch kit with a lightweight Fidanza Flywheel 7000km ago), along with that a few basic suspension parts such as cv axles etc. The car was completed and handed over to me after a decent-sized bill incl OEM parts etc. Upon driving it in gears 1-4 (never went higher) I had a hesitation which felt like the car would cut gas/shut off mid-drive mainly when boost was building etc making the car undrivable, along with that the car sounded like a tractor which was assumed to be the clutch/transmission (possibly the crankshaft out of place/hitting something). The odd part was the car had the same existing P2188 code (rich fuel at idle in bank 1) that the old engine showed, all that being said the car was sent back to adjust the clutch and address the code, which meant new OEM 02 sensors, and repositioning/refitting the clutch with a new clutch release bearing (which I also got a bill for), they also decarbonized the engine because they said there was bad gas in the system leading to that bogging, which lead to them telling me to drive 3-4 tanks of gas (the car only sees 94 oct) and see how it feels otherwise it's the injectors. Time went on and the same problems persisted, which started to create a idel/cutout issues etc. This lead me to taking it to another shop and replacing all 4 injectors with OEM ones because they said it was dripping fuel into the cylinders overnight, along with both long and short-term fuel trims being off. After hoping that would resolve the issue it didn't, which also lead to a crankshaft position sensor code (P0335) leading me to take it to a 3rd shop where they fixed that and re-did the timing along with checking for boost leaks, vacuum leaks, exhaust leaks (they also ensured the ECU was flashed to the correct parameters as they also did tuning for many reputable dealerships/brands) etc. As it stands the car only shows these over-boost symptoms in gears 5 and 6 which is far better than all 6 (if you shift into gears 5 and 6 above 4000km where boost is already built the gear holds all the way through redline, however, if it's before 3000km and its building it's sure to cut out), and the clutch continues to make that noise, it's scheduled to go back to the same Mazda to have the clutch looked at for the 3rd time and they want to look over the over-boost issue and rich fuel as they have a new foreman. A few other notes, I kept the turbo from the blown engine on as it was a newer OEM ko4 which Mazda ensured because the turbo that came from the wreckers had more shaft play (leading me to think there could be a wastegate issue, but there isn't a code maybe... The car as it stands right now is completely stock and only has the two codes listed above when hooked up to an OBD2. If it helps I have all the parts/shop notes from both mazda and the other 2 shops available which are somewhat more in-depth.

    I know the post is long and has a lot to follow but I appreciate all the help as this issue seems to be stumping many of my local shops along with a Mazda dealership, and was wondering what opinions/experiences you guys may have. Appreciate it.
     
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  2. Bighern9999

    Bighern9999 Greenie Member

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    Did you find out the problems for this?
     
    Bighern9999, via an iPhone, Sep 7, 2023
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