The issues were more with the tuner's time and expectations with the aftercooler / heat exchanger than any real problem. I bought these used so it was not a complete kit. He did not like the way the heat exchanger was previously installed and had to do some fabrication work he wasn't expecting. Same with the water pump and horn I picked up - where to put it, how to mount it... No big deal, just more time.

 

Finally got the S back. The new setup dyno'ed at 345 / 203 on the dynojet with a surprising 10.2 lbs. of boost.

I am happy with the hp and torque numbers. Tuner said he could have gotten another 10 to 15 hp if he went more aggressive. The original 6 lb pulley only delivered 4.5 lbs on the dyno. I assumed the lower boost was primarily due to the full exhaust and was expecting the new 9 lb pulley to actually deliver around 8 lbs or so. I am really surprised by the 10.2 result.

On one of the first pulls with the new setup the aftercooler blew off the intake. This pull basically gave a non-boosted resulted with the Novi hooked up - 155 hp, about 50 hp less than stock... Interesting, I had no idea there was that much drain by these things that has to be compensated for.

Anyway, all is not good with the tune. I posted another thread here looking for some help: https://www.s2ki.com/s2000/topic/103...r-help-needed/

 

Here's an update on my crash course on FI. I had serious issues with the tune on when I got it back after aftercooler, Series 2 and higher boost installation. The dyno numbers were solid, but it was not right. Went with Evan's for an etune. Had issues with my wideband - nightmare, but figured it out.

Jeff gave me a tune, better, but not still right and I wasn't comfortable doing the pulls. He tweaked it, still not right.

When I upped the boost the fuel pump was in question. The assumption was it had the Comptech pump that came with the original kit, but I wasn't sure. So, with the issues I ordered a Walbro. Over the past 3 nights I took out the interior, installed a new stereo system and installed the new pump.

When I got to the pump I discovered a mouse had made a nest at some point in this garage queen's life right on top of the pump housing and chewed the ground wires bare. Both power wires had some nibbles and exposure too, but not a bad as the ground wires. This definitely could have created some voltage problems. Lucky the car didn't catch on fire.

Anyway, I pulled the pump and the same Walbro was already installed... I went ahead and replaced it, fixed the chewed up wires and ran the new pump to the battery through a relay. Went for a short drive tonight and it was very willing, no hesitations and idle is much better too. All seems good.

Hopefully more logs for Jeff tomorrow.

 

Excellent. Good job on figuring it out. You certainly aren't the first S owner with mouse problems in that area. Its becoming a more common story. I wish Evans did e-tune with Haltech, I hear so many good things about his e-tune program.

 

Hey man welcome as I too just bought a s2k but for the second time lol. There are a few shops in Huntsville that can tune your car one of the shops tuned my old turbo s2k and did a good job. If you need a really good tuner PM me I have a friend that lives in HVille that tunes all kinds of cars from Lambo's to s2k's and he has owned 2 s2k very knowledgeable

 

I'm in Huntsville every two or three months for work. I'll reach out before my next trip. I'm going to let Jeff get it close, then I'll get it on the dyno to polish it off. I'll reach out before my next trip. Thanks.

 

The problems continue, but slowly figuring things out. I was still having some stalling and rough idle issues. With the battery being 4 years old, I thought I'd give it a shot. Went to Advance and got an Optima Yellow top. Did the swap in the parking lot and stalled at the first light... I was pissed, but I don't have to worry about the battery.

I looked at some other tunes again compared to mine and did some slight adjustments of O2 feedback, raised the idle to 950 and a couple other things. It's not right, but the stalling seems to have stopped. I have clearly over corrected and will work on dialing it closer before sending more logs to Jeff. I am now convinced the problem is in the tuning.

Another concern, my aftercooler has been extremely hot since I got it installed. Did some searches to see it was normal, of course its not normal. Also, the water pump used to be very loud at startup and the noise has gone away. So today I pulled the bumper to check things out and reroute the water lines as suggested by MugenRioS2k and CoolGuy094 (maybe others). Well, the lines were already run "right" except one line from the exchanger to the pump was pinched twice. The pump seemed to be working fine. I went to Home Depot and picked up a couple copper 45's and redid the pinched line. Primed the pump, used a bottle of water wetter and put it all back together.

I went for a quick ten mile run, when I got home the aftercooler was as cool as could be.

 

Which aftercooler pump did you end up using? Good job on resolving that pinched line issue, I guess the shop that installed it can be blamed for that one?

My tuner recently replaced my battery as well; not sure if it actually helped to resolve any of my street driving issues but mine was 5 years old or so as well so better safe than sorry I guess.

 

Keep an eye on that optima. The stock size optimas historically haven't performed well in hondas. I've tried them on three different models and had to return all three. If you search around, you'll find my experience is not uncommon.

 

Buy the optima group 34/78 and be happy. I had one that lasted 6 years in my s2k lol.