spacecad3t wrote: Good suggestions, but worth noting the elevated idle predates both the MAF conversion and the F9Tech DME — the issue existed on the stock AFM and stock DME. So calibration mismatch between the MAF curve and DME at idle flow rates isn't the cause, though it may be a contributing factor to the current state.
TPS is confirmed mechanically — back-probed at the DME plug and also visually confirmed throttle plate returning to full close at the hard stop. Stop screw has been reset twice with no change to idle.
ICV block test has been done — with ICV hoses capped and electrically disconnected, car runs rough and needs bypass opened to survive. So ICV is the dominant air path.
The one suggestion I haven't done is the pressure test at 2-5 PSI rather than smoke. That's a genuinely new method for me on this car. Can you walk me through exactly how you'd set that up on this specific intake configuration, and what you'd expect to find that smoke would miss?
Sure. A low-pressure “boost leak style” test works well on the 944 NA because it forces air out of tiny gaps that may not show smoke, especially if the smoke machine output is low, the leak is on the underside, or the leak only opens when a hose/gasket is slightly pressurized.
On your setup, the cleanest way is to pressurize from the MAF/J-boot side and seal the system so the only place air can go is out through leaks.
You need a way to introduce regulated air and a gauge. The simplest is a rubber plumbing test cap or silicone coupler with a Schrader valve installed, clamped into the intake boot where the MAF meets the J-boot, or directly onto the J-boot if that’s easier with your hardware. You want the throttle closed, engine off, key off.
Then you have to block the big intentional openings. Cap or pinch the brake booster hose at the manifold. Cap any remaining EVAP ports if any are still present. Decide what you’re doing with crankcase ventilation for the test: since you’ve vented to atmosphere, you’ll either hear air rushing out of that vent (which is expected) or you can temporarily cap the crankcase vent line so you’re strictly testing the intake manifold and runners. If you don’t cap it, it can mask smaller leaks because the system won’t hold pressure.
Regulate the air down to something gentle, around 2 to 5 psi. Do not go higher; you’re not trying to “inflate” seals, just reveal leaks. Bring it up slowly and listen. A system with no meaningful leaks will build pressure and then bleed down slowly. With leaks, it won’t build much at all and you’ll hear it.
What it finds that smoke can miss is usually one of three things. One is injector seal leakage that only opens under slight pressure, especially if an injector isn’t seated perfectly or the rail is stressing it. Two is manifold-to-head or throttle body gasket seepage that’s too small to show smoke but will hiss under pressure. Three is cracks or pinholes in hoses or caps that don’t pull smoke through because they’re not in a strong flow path during a smoke test.
How to pinpoint once it’s pressurized is mostly ears and soapy water. Spray a soap/water mix around injector bases, the manifold gasket line, throttle body gasket and shaft area, ICV hose connections, and every capped nipple. Bubbles are your friend. If you have a mechanic’s stethoscope or even a length of hose as a “listening tube,” it makes it much easier to localize.
Given your symptoms and the fact that the ICV block test behaves as expected, my bet for “what smoke missed” would be a very small leak at an injector seal or a cap/port that only opens under pressure, or a leak at the throttle body shaft area that doesn’t respond to carb spray. The pressure test is good at making those obvious.
If you tell me where your test cap would be easiest to install (MAF outlet, J-boot, or throttle body inlet) and what you currently have for crankcase vent plumbing, I can tailor the exact cap/pinch points so you’re not chasing a “leak” that’s just your vent-to-atmosphere path.