I have been following this thread and the title suggest that the root cause of the problem was identified as the air filter. Based on the information presented, I’m not convinced though. Let me explain:
A clogged air filter can have significant impact on a car’s performance. I find it difficult to image to that a brand new filter, no matter how crappy, would have such an impact on the car’s performance. There is no way that is caused by just a crappy filter that might have a bit more resistance compared to a new, proper, filter.
So unless this new, crappy, filter had some serious defects or was installed in such a way that the rubber seal was pulled off and blocked the air inlet or it had some serious manufacturing defect, I don’t see how it could have impacted the engine performance this much.
The easiest way to verify is to put this filter back on and see if the problem returns. That would prove beyond doubt it was actually the filter. Otherwise, I find this cause not very plausible.
some thoughts/comments on some of the details and information provided:
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He got the UFI filter blowed, to remove black soot particles, removed the Lumax and installed UFI, ran diagnostics, updated some Software (apparently he said).
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This is the problem why the story and pointing to the filter as the root cause is not plausible. Several different items where changed all at once. We are not quite sure what or how. But afterwards everything was fine, so why was the filter the culprit?
If you want to do a proper fault analysis you need to take it one step at a time, or you will never know the real problem.
A few other thoughts/comments:
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From 0-2.5K RPM there was sluggish acceleration and very less torque, glaringly experienced on inclined roads, and after that, a sudden torque surge, and rpm used to shoot up till 4K.
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This doesn’t seem to be consistent with an air filter being clogged or reduced air flow. If anything at low revs a clogged filter will perform relatively better than at high revs. Less air to go through, less resistance relatively speaking
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Check out the thickness of the fibre layering on the outer surface. Its common sense, that the thicker the filter, the less the air that gets in. The design of air filter is a thin line of art.
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Yes, but on a new clean filter the thickness won’t make a huge difference, at least not to the extent you noticed on engine performance. To see such degradation it needs to have a substantial higher resistance than a normal proper filter.
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Since my car had done 7.5K, there was 7.5K life left in the UFI filter.
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NO, absolutely not! Filter life has not necessarily to do with how many km you do. (even though your manual will say so, its based on averages. Especially in India with many very dusty places a filter could get clogged within a few hundred kilometers, less if you find yourself driving on very dusty roads.
(Once I had my Royal Enfield bullet serviced, changed the filter. We found ourselves driving on a sand road with some 30 bikes, in a huge sand cloud for about 10km. Several of us, including mine stalled due the (new) air filter completely clogged up with hardly any miles on it.)
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Since the torque in those cars is more, the little reduction in airflow will result in marginal reduction in power, sometimes which can go unnoticed. But surely an analysis of Mass Air flow should throw up the issues on the result sheets
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Don’t think so. Torque is a function (a.o.) of how much fuel and air gets injected. What would you like to analyse from the MAF? If you want to do a measurement you would have to find a way to measure pressure drop across the filter. Which on a non turbo car could be achieved by looking at inlet air pressure against atmospheric pressure. Change the filters out and see if you get a noticeable difference. Easier is what I suggested earlier, just swap the filter back and see if the problem returns.
So I am not convinced at all that the filter was the culprit. There are too many contradictions, things don’t add up and I see no evidence of a thorough methodically step by step trouble shoot approach. So to blame it on the air filter, in my opinion, is pre-mature or at least not proven at all.
do you still have that crappy filter? If so, stick it on and see what happens. If it does impact the engine performance immediately and substantially, cut it open, because I find it very difficult to imagine that the thickness of the mould alone can cause this effect.
Jeroen