Just intercooled 1kz, now surging

[uptomynutsinruts]

Hi all,

Just intercooled my 1kz using a prado setup, now I have a weird problem which I believe is my TPS, the truck will surge - by surge I mean it basically dies, engine light on, revs drop, it happens for about 1 second, but sometimes will do it 4 or 5 times in a row.
Have tried setting TPS using voltmeter, turned ignition on, found 12v going in, coming out at what would be idle is around 1v, and at WOT is about 4v, any ideas what to do?
Is a real pain in the ass

[tweake]

pull the ecu code. should give you an idea whats at fault.
sure you didn't knock any plugs off when you did the ic ?

[uptomynutsinruts]

Will see if I can pull a code in the morning hopefully, after 4 times of taking ic off to adjust tps then reassembling and test driving I had to stop before I got really irritated and broke something lol

[slide]

the truck will surge - by surge I mean it basically dies, engine light on, revs drop, it happens for about 1 second, but sometimes will do it 4 or 5 times in a row

When?? at idle? open road speeds?

[KIWI_TERRANO]

Mine use to do that when u tried to wind boost up, so it could be the same since it intercooled maybe???

[kbushnz]

If the TPS was working fine on the old setup then it should be fine with an intercooler fitted (mine had no issues) I would suggest its to do with the MAP sensor.. Is it plugged / plumbed back in to see the pressure in the manifold etc etc. Also if you have bumped up the boost as it will cut out at about 14 psi.... Is the EGR system all plugged in and vac lines correct.
Some guys have experienced problems in this department also.

[uptomynutsinruts]

Right so prepare your ribs for laughter, made a serious rookie move , forgot to tighten an earth that runs to intake manifold (never traced what it was for as when I found it I just about cried with relief haha) so after that she's running bloody strong, heaps better pull and cruises up hills at 80-90 that I used to have to change down to third and end up around 50 by the top. So for everyones information, it missed etc mainly when driving (obviously bumps in the road jerking the earth around) It was also resistant to starting which I put down the the vibration while trying to start causing the earth to move. Also no fault code was produced.
Thanks heaps for all your suggestions.

[catalystracing]

Not going to laugh, Ive done that kinda thing too many times also......

[uptomynutsinruts]

Just stoked it was an easy fix, amazing the difference the intercooler makes, should've been factory on all 1kz's