Well, yesterday was fun!
Took the car in to the stealership for an alignment and, after finding a loose lower control arm bolt, it also became obvious there was an EXTREME fuel leak from the 5th injector LPFL T connector! This scared the shit outta me - I was just driving to town (20 mins) and didn't have my extinguisher with me as I was cleaning the interior. Thankfully disaster was avoided but I was very alarmed to discover the plug from the AeroMotive hose was the culprit.
Being new to push connectors I figured one of them would be an issue - very concerned to see fuel leaking profusely (we're talking almost a stream) out of the brass plug in the pre-packaged T. This was VERY close to the downpipe and would have been the end of the car if it happened to catch fire. I had done a hundred KM or so on the car as break in procedure for the LSD - not aggressively accelerating or pushing the car. My only thought is that when I came out on the pavement before going to the dealership, I did put my foot down for a quick second, had felt the car hesitate and lifted - I was thinking perhaps it was a tune abnormality (I've had boost surge before). NOW, I think that's when the fuel pump supplied maximum pressure and blew past the sealant and started leaking.
I spoke to Ron @ Whoosh and it seems to be a one off - he doesn't package this item but takes the hose from AeroMotive and combines it with the SplitSecond controller for his package. In any case, I think Ron will be removing the plugs from the kits he sells and allowing the end user to install them. This would be avoided if that were the case - the main issue is that the plug HAD sealant on it. I didn't even think to tighten it due to this.
Just to be clear, I'm not voicing my frustration at Ron, but AeroMotive. Ron seemed to be receptive to my issue and understood the ramifications of this happening without the car sitting at the dealership when discovered.
So.... fun stuff number 2!
On the alignment machine the car was having issues - the rear end is apparently tweaked so that the passenger rear is toed in 0.7° which is non-adjustable and out of spec. So... Ford tech tells me it's the rear end that's bent - the spindle on the outside by the hub is knackered and there really isn't a fix for it. Fuck sake....
THIS is the reason I bought a Fiesta ST and not a German competitor - complete rear axle is $504. So... that's now my strategy. Take the new axle, clean it, POR-15 it and then get it re-aligned and confirmed to be in spec.
Can project cars NOT be such big projects some time???