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I've been busy over the past month after work everyday. My initial post plenum problem was my 90 TT 5spd would idle up at start up, and die as it started to settled down into its normal ~800ish rpm idle. At that point, the only things different were the DW 555 injectors, a used IACV (lost the spring in mine cleaning it), and the Eprom itself. I found SEVERAL connection issues (broken wires, etc) in the harness(es) and so I went nuts. I pulled the engine, replaced the engine harness with a 95 TT 5spd harness, alternator harness, and battery harness--along with 120k kit, high pressure steering line, and a few other odds and ends. So Sunday I start the car to bleed air out of the coolant (first start since the major work) and already I was having problems. Slightly rough idle, and eventual stalling. Needless to say I was/am not happy at all. I checked and rechecked the timing belt alignment, and checked and rechecked the pictures I took of it. I'm 1000% sure that this is not timing belt related now. $$$$ and time out the door and I still have the same blasted issue that this was "supposed" to fix. To me and others it sounds like it is running out of fuel, but mind you until it starts to settle down to its normal idle (as in as long as it is fast idling) it sounds good and clear. Just to detail a little more, sometimes it sounds like its dying from lack of fuel, and every now and then it sounds like someone shuts off the key. So I've done some searching, disregarding (maybe foolishly) items that I have replaced like the CAS, ECTS, O2 sensors, spark plugs, vacuum leaks, and so on and so forth. I've come across a few posts about a member here that had similiar issues except his were while driving the car. His fix? The Fuel Pump Control Unit. I read further that we both have 1990 TT's, and that the 90 model was somewhat prone to FPCU failures. I pulled mine out and although there are no burn marks or busted capacitors that I can see, I'm wondering if it can fail without any noticeable signs? At this point, if you're still with me after that novel, I'm looking for more help yet again. Any ideas are appreciated, thanks to everyone who lends a hand. For reference, here is a list of things I've replaced/done. DW 555 Injectors
Injector O-rings and injector connectors
Fuel rail/lower intake seals, pressurized the rails with air under water = no bubbles/leaks
All fuel hoses and filter
Fuel and coolant temp sensors
All vaccuum lines
Installed an HKS EVC
Manually rotated CAS, all injectors are clicking/firing
Reprogrammed ECU from Coz for the larger injectors
Performed power/balance test = good
Swapped air regulator for another, both ohm out properly and can watch the bi-metal device work as it's supposed to.
AAC valve operates correctly according to Blazt
Initially the dipstick o-rings were letting air escape, a boost leak test fixed that.
Swapped out MAF with a known good one, no result
Plenum torqued to spec in a criss-cross pattern.
Fuel pressure at idle is 37 psi, pressure regulator unplugged is ~44psi. As the car is in the process of stalling, pressure goes up several pounds.
Both O2 sensors are new and correctly wired up
Code 55
94+ CAS
engine coolant temperature sensor
120k kit
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