Hard Brake Pedal

[Tom @ Fast Forward]

We have had a couple with Hard Brake Pedal as a result of low brake boost. Thanks to James and Bill and PR Motorsports, we have found the problem. The problem is due to the location of the outlet side of the Idle Air Control valve. At present, it is connected to the Vacuum Distribution Block. Looks like I made things better until I broke it. With the first kits, starting in 2004, we had the IAC mounted on a bracket between the supercharger and the engine. The IAC outlet went to a tee in the hose from the PCV valve to the throttle body adaptor. All was well with the world. EXCEPT the bracket was weak and broke. We then moved the IAC to a stronger bracket on the firewall. The outlet of the IAC was connected to a tee off the other side of the throttle body adaptor. All was still well with the world. Then, we cleaned up the hoses and added it to the Vacuum Distribution Block. All was well with the world for most of the installs but a couple had a problem. Even those that are OK are still not great but we just never noticed.

Well, the absolute cure is to connect the outlet of the IAC valve to a tee in the PCV valve hose. Then, all will be well with the world once again. Rick at PR Motorsports will send me a picture later tonight and I will post it ASAP.

I am also curious if this will cure the random "EGR LOW FLOW" CEL as well. Frankly, it may solve several of the mysterious CELs?

All it takes is a piece of 3/8" standard fuel line to go from the IAC to the PCV. Then cut the PCV hose and install a 3/8" x 3/8" x 3/8" barb tee (local ACE hardware) and a 1/8" pipe plug (local ACE hardware) to plug the now unused 3/8" barb in the VDB that used to go to the IAC.

Even if you are not having a problem, I highly suggest this modification.

[beatle]

How does this affect those with the stock throttle body and the IAC mounted to it?

[Tom @ Fast Forward]

You have no problem at all.

[ThomS]

Tom thanks for checking this out and finding the brake problem for me and anyone else that might of had this problem. I will get on it this weekend and let you know how it turns out. Also thank James and Bill at PR Mortorsports.

[Tom @ Fast Forward]

Here is a picture of Rick at PR Motorsports modification.

[maggie]

Thanks for the fix. As a 'spirited' driver, my brakes loose vacuum rather quickly. Not fun in the mountains or on autoX. Maybe the P0106 gremlin will disappear as a result too. :cool:

[Tom @ Fast Forward]

You are welcome. I'm just sorry the problem occured. Let us know if it helps your brake problem. My 99 had the kit on since Oct. 2004. Never had a problem? I think it also had to do with how 'open' the BTB was. The more open it was, the less air flowed through the IAC and the less likey you would have a problem.

[maggie]

:offtopic: At the risk of going off topic; I would like to know if anyone else experienced a full boost/WOT event when entering boost as a result of having the IAC lines reversed? It happened to me after the install last year and it was a quite exciting experience as I took my test drives (2k rpm to red line in half a second!). I still have my doubts as to whether that was the culprit as the cruise control was erratic after the install also, perhaps from the under dash connections being disturbed. The symptoms went away after reversing the lines and jostling the cruise connectors. Words of wisdom...check, double check and have a friend check your work because even if everything is going well, you have obviously overlooked something.

[ScottA]

I have to admit that in my excitment I too reversed the IAC lines , I even double check everything twice and made the same mistake twice.:no: The only thing that happen to my 2001 on the test drive was a rough idle and a moaning sound from the IAC itself. As soon as I heard the IAC noise I knew what I had done and everything was fine as soon as I corrected the line mistake. I had no run away problem, but I had the situation corrected within a mile or so. :sweatdrop:

[tann3r]

And here I was thinking I did an excellent job bleeding the brakes! I guess now is a good time to move the bypass signal over to the VDB while I'm under there messing around.

Thanks for the easy fix!

[gludlow]

Could someone who implements this post some "before and after" pics? I'd appreciate it!

[Dr Evol]

Thanks for the info Tom! I have never had what I would call good braking since the install of the FFS 3 years ago. I have bled my brakes several times over the years trying to improve braking performance with little improvement. I can't wait for the autocross this weekend to see if this mod has made a difference.

[rins]

Yes! this fix my hard brake pedal and idle issues! :yes:

[ThomS]

All is well with the World. expecially when the Air conditing is on..

[gludlow]

Got it done! Brake pedal feels a little softer, but I honestly can't tell the difference in braking ability. I wasn't having any problems or CELs to begin with.

Oh, and by the way, make sure you buy the 3/8" INTERIOR diameter, not EXTERIOR diameter barb tee. Oops! :eek:

[Tom @ Fast Forward]

You must be one of the 95% who had little or no problem.

James sent me a note and said it not only cured the brakes on his 02 but eliminated the random codes. I think ThomS will be the key. If it eliminates his random codes, we may finally be able to remove the Joe BTFSPLK designation? Nah. He'll find another reason to keep the title. ;)

[ThomS]

You are right. I own that title. But for now The brakes feel great even when the Air conditioning is on, and you felt the hard brakes when I was out there so you know. Totally fixed and no code since I left you home on that day. about 4,000 miles all is well with world.



You must be one of the 95% who had little or no problem.

James sent me a note and said it not only cured the brakes on his 02 but eliminated the random codes. I think ThomS will be the key. If it eliminates his random codes, we may finally be able to remove the Joe BTFSPLK designation? Nah. He'll find another reason to keep the title. ;)

[Tom @ Fast Forward]

Seems like a product that WAS about 98% perfect is now getting closer to 100%. Now. if only ECool worked. :biggrin:

[liddown]

+1 Did the mod last night and all just seems better... Idle improved, brakes felt better, oh yeah and the sun felt warmer ;-)

Highly recommended very easy mod.....

[Steve in VC]

Tried it and agree on all counts (the sun does feel warmer....)

Thanks for the great fix!

I also found if you adjust the idle a bit high, you get the same problem. If I could make one request on the kit - make the idle adjustment screw easier to reach!!!!!!

[Tom @ Fast Forward]

Did you find the high idle/brake problem before or after this fix? I could understand it before the fix but it shouldn't happen after the fix.

[Steve in VC]

I resolved the high idle speed before the fix.

I may have a bit of a sticky throttle cable that contributed to getting the right idle setting, I kept over or undershooting. If I noted 1100RPM (without airconditioning) effected the brakes, and by blipping the throttle to get back to 850RPM would fix that.