That's a long list and I don't think I'll be able to give you all the details but I'll try to give you as much. Been a little busy lately and I don't really get much wrench time during week days.Thanks for offering to help.
Number one point; is S.A.I filter gone or not or partial gone?
In addition: I'd also like to see see from you and everyone with 06-07 VVT that has CAT issue(s):
History of engine & vehicle:
- All DTC (codes) every seen/recorded.
- Compress test, done by the book (FSM). i.e. Engine at operating temp. Power to fuel pump disconnected (wire harness block under body just below rear left door). Gas pedal fully depressed (this opens throttle body butterfly, the safe way). Full charge on battery ( keep a charge on battery, while testing) so you get a minimum of 250 RPM as each cylinder tested.
Logs of and in what weather condition and OAT:
- Has intake manifold every been off (reason it would have been: S.A.I pump or it's main SW work, starter replacement, intake gasket replacement, rodent chew damage under intake manifold like knock sensors wires, starter wires, S.A.I wires),
- Tuned. Always or just runs fine never needs tuning.
- Air filter. Has its seal been found curled, which allows excessive dust into intake. Has filter been replaced every 20K miles or sooner under dusty conditions.
- Any vacuum leaks
- Any exhaust leaks, from rear of either CAT up to heads.
- Conditions vehicle driven in. Here I'me very interested in dusty conditions driven in. Which if so, we tend to see a lot of dusty built up under intake manifold, on S.A.I pump and main switch and in thick bottom of engine valley.
- Prolonged idling (yes, no, kind of, don't know). The OEM states do not prolong idle, and defines as 20 minutes IIRC.
- Ever overheated.
- Does it tend to run hot (over 197F).
- Any fuel boiling episodes.
Engine coolant temps (ECT).
Long term fuel trims (LTFT), while RPM & MPH steady and at what are the RPM & MPH.
What are intake air temps (IAT), outside air temp (OAT), sun, overcast, night during times logs are recorded of other data points.
CAT temps.
I know it's a lot to ask, so just get what you can.
Also if compression low or bad and clues to reason for it. I see so often where intake manifold removed without cleaning top engine really well first. Sand drops into intake ports, and or intake ports not protected and or not vacuumed while expose/and before buttoning up. In fact, it is such a big deal to me. I red flag any inspections, if history show intake manifold every off.
Another way sand gets into cylinder, is during spark plug removal. This is really only issue if coil top seal, have been allowed to get to old before plugs replaced. As they rubber seals shrink. It's more of issue to be concerned with. If vehicle in dusty or sandy conditions. We than tend to see sand on top of heads covers around coils and in valley.
Also I find , 1 in 4 air filter seal curled, allowing air/dust to bypass filter. Dust then goes directly into intake ports. This is due to carelessness, while installing air filter.
We also want to know if prolonged idling is a common occurrence or lot's of short drives (not making operating temp). Both can damage CATs.
If fuel mixture to rich, CAT can ignite and burn up.
CAT's are also damaged by coolant, so coolant issue are worth nothing.
Air leaks into CAT, will also burn them up.
Additionally, impact to a CAT can bust then up up.
For data collection: I use either Bluedriver or more recently OBDIImx+ and my smart phone (iphone). To watch and record data (logs) as I drive. Very useful tools, which I can also scan for DTC and clear them.
What I'm try to establish; if any other reasons for CAT failure and is the filter of S.A.I pump gone. Also what is compression and any clues in history as to why.
Here"s some screen shots of live view from my iphone and log I emailed myself (spread sheet). These are from and 07LX w145K I bought last month. I was doing a HWY high RPM burn out to clear any carbon & muck build up off CATs, A/F & o2 sensors. These were take on drive back from point of purchase at ~94f OAT, day of full sun, at ~5PM, just as starting to get overcast.
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Screen shot of iphone while stopped, next day.
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I found ECT and AT fluid #2 (automatic transmission fluid #2) temps getting to high, due to the typical radiator fins clogged. Likely guy who sold to me, probably didn't like they way in was running in summer heat. I've since washed muck from radiator fins, and drop ECT & AT temps from what's seen in spread sheet logs above, by about 20F.
Pictures of muck in radiator.
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Also, I was wondering, don't you think instead of routing an independent air filter to SAI pump, why not stretch the hose it into the factory airbox? Seal the connection real good and maybe add another small filter inside the filter box (for overkill protection) Do you recon any drawbacks? What's your opinion.