1+ or other issue...need some insight

[jessefrank]

Lately my car seems to be runing rich or having other issues and I'm kind of stuck as to what it maybe. I had a boost leak for awhile, but since fixing the leak it has stayed the same. Currently I'm thinking it could be one of 3 things or a combo of them: a bad cat, failing front O2 sensor or the actual REVO software itself.

A little back gound info; I have a '02 1.8t with the following performance engine add-ons: REVO stg 2 software, Bosch 380cc injectors, forge DV and AFE drop-in filter. I don't have a boost gage, but recently did the boost leak test/fixed my leak. I dont' have any CEL's. I don't have access to VAG-COM. I also am running a de-tuned (per REVO spec) REVO stg 2 file (due to not having a TP and full exhaust as REVO specifies to get full potential [aka increased boost/timing settings] from stg 2 software).

These are my symptoms:
1. If I get on the car, even a just a little I get a strong/rich exhaust smell. I can't find any exhaust leaks but will have it up on a lift this weekend for a better look though.
2. Also if I get on the car at all the turbo will be glowing red afterward (the degree of which varies, but it isn't good). I know this is common on a chipped K03 that's driven hard, but it never happend much if at all before (even after getting REVO Stg 2); now it seems to happen more often even without really driving it hard (poor turbo ).
3. Lastly, since getting the stg 2 flash almost a year ago I was having an abnormal amount of buildup on my sparkplugs (black gunk and they were fouling out). Also I kept getting a more than normal build up of the black crud on my exhaust tips. Since getting the boost leak fixed and a injector o-ring leak fixed they have appeared to be fine; so I'm not sure if these are related to my current issues or not.

Since REVO had to de-tune my program and I'm still running 380cc injectors; could this make the car run overly rich? Could my front O2 sensor be going out (not enough for a CEL) and cause the A/F ratio to be way off on the rich side? Or could my cat be failing (again, no CEL yet) and causing too much back pressure on the turbo causing the above symtoms?

I have a ER testpipe waiting to be installed which will help if it's the Cat going, but I don't really have the money to start buying O2 sensors, reflashes, different injectors, etc chasing the issue down that way.

Thanks in advance for any insight,
Jesse

[Carlitos]

did you "de-tuned" your car and still have the 380cc injectors?

[jessefrank]

Yes...I have 380cc injectors in it now. REVO states that if you don't have TP and full exhaust (IC optional) w/ stg 2 that the boost and timing settings are set at a certain #. I dont' remember the #'s off hand, but I was told by the REVO dealer that it pretty much produces less HP/TQ and helps maintain the life of the K03 since w/o the Test pipe/full exhaust there is too much back pressure on the turbo for it to safely operate at the normal stage 2 settings. Also I had the revo thsi way for while with out this issue; so I don't think it is the software, although I could be wrong.

I'm leaning toward a restriction in my cat causing the turbo to heat up and exhaust smell in the cab (possibly blew a gasket due to the pressure) and possibly the O2 sensor as well. I first thought the front O2 may be bad, but my gas mileage hasn't really been horrible and I don't have a CEL. I would think the the revo software wouldn't allow it to run so rich as to dump fuel into the exhaust thus heating up the turbo...unless the front O2 is misreading the A/F ratio.

[jessefrank]

Bump