Boost leak from hell!

[Gubien]

I did another boost leak test yesterday!

Took of the MAF, blocked the TIP and connected the pressure hose that goes to the N75 from the charge pipe directly to the hose that goes to the actuator.

Removed the oil filler cap. Disconnected the hose that goes from the breather valve to the tip and plugged the hole in the tip.

Pressurised the system up to 0.8 bar and there was absolutely NO sounds, other than bubbling sound from the oil circulation. The pressure whas decreasing steady, but soap solution didnt show ANY leak.

Tried disconnected the charcoal filter hose and plugged it. In the same line I also plugged the hose to the inlet manifold to close the system totally.. Still just bubbling sound.

Can I have leaking internals??? The car does not use any abnormal oil or water(oil, about 0.7L every 10.000km). No smoke from exhaust etc.

Still the car wont boost steady above 0.5 bar!

 

[Willie]

Jees bud, this isn't looking good. Sorry can't help with this one. I'm not too clued up on the engine side of things

 

[DanAPR225]

any fault codes mate?? when was your dump valve last serviced?

 

[wild willy]

Do any of your mates drive a LCR who you could swap out some of the sensors with to find the fault through a process of elimination.
Check that you are getting a fault code. If not do a 118 log and check if the duty cycle on load is maxed out at 5.1. If it isn't the n75 valve is probably faulty or the wiring to it is.

 

[Gubien]

any fault codes mate?? when was your dump valve last serviced?

No faults codes. I've changed between a stock, bailey and forge, they all do the same ****

 

[Gubien]

Do any of your mates drive a LCR who you could swap out some of the sensors with to find the fault through a process of elimination.
Check that you are getting a fault code. If not do a 118 log and check if the duty cycle on load is maxed out at 5.1. If it isn't the n75 valve is probably faulty or the wiring to it is.

Unfortunately I've changed alot of part myself. MAF(twice), N75, DV, breather, gas pedal(Still only shows 78% on full pedal).

What do you mean by "If not do a 118 log and check if the duty cycle on load is maxed out at 5.1."?

This is the best it can do:

Group A:	'115			
	RPM	Load	Absolute Pres,	Absolute Pres,
TIME				
STAMP	 /min	%	 mbar	 mbar
908,6	1720	15,8	1000	1010
909,13	1680	15,8	1000	1000
909,65	1680	69,2	1760	960
910,24	1760	73,7	1770	1050
910,79	1840	80,5	1810	1140
911,35	1920	88,7	1870	1250
911,9	2040	97,7	1920	1350
912,43	2200	112	1990	1490
913,01	2320	123,3	1930	1630
913,58	2480	136,1	1850	1800
914,21	2640	130,8	1830	1720
914,77	2840	125,6	1820	1620
915,37	3000	124,8	1820	1550
915,91	3160	124,1	1820	1550
916,4	3280	122,6	1820	1560
916,96	3440	122,6	1840	1560
917,55	3560	125,6	1850	1580
918,1	3720	127,1	1850	1590
918,65	3880	126,3	1840	1580
919,19	4040	123,3	1830	1600
919,73	4160	124,1	1820	1580
920,32	4280	124,1	1810	1550
920,94	4400	123,3	1800	1550
921,54	4560	121,8	1770	1560
922,12	4680	121,8	1770	1530
922,68	4800	121,8	1770	1550
923,26	4960	124,1	1760	1560
923,76	5040	124,1	1770	1560
924,33	5160	123,3	1790	1590
924,96	5280	129,3	1810	1580
925,55	5400	131,6	1840	1620
926,12	5520	137,6	1880	1630
926,66	5640	145,1	1930	1710
927,13	5760	157,9	1940	1830
927,71	5880	145,9	1930	1880
928,3	5960	146,6	1920	1840
928,88	6040	141,4	1890	1780
929,46	6160	126,3	1870	1740
930,01	6280	127,1	1830	1700

graph of it, as you can see, it just "sniff" to the correct boost and then fall back:

 

[wild willy]

The log you just posted is from channel 115.
Post up a log from channel 118. It will show the duty cycle of the n75 valve. The results of which may indicate a faulty valve.

I think you can rule out a boost leak since you have tested it with no signs of any leak present.

 

[Gubien]

Now when I think it through there might been some VERY tiny bubles around the N75 stud that goes to the TIP. The clip might be a cheap ass one which bites the silicone! I will try to sort this out by getting a different clip and eventually cut a bit of the worn piece off.

Then make a 4.th gear log of both 115 and 118. I'll be back

 

[Gubien]

Fixed the little leak at the TIP and put a new clamp on it, tighten it well.
I can see an improvement, but I dont know if it the fixed leak or just the car that has adapted to the conditions.

1.st run in 4th.

	Group A:	'118			
		RPM	Temperature	Load	Absolute Pres,
	TIME				
Marker	STAMP	 /min	°C	%	 mbar
1	313,47	1360	30	0	1060
	314,03	1400	30	0	1060
	314,61	1480	30	100	1080
	315,17	1560	29	100	1140
	315,66	1640	28	100	1180
	316,22	1760	27	100	1210
	316,76	1840	27	100	1270
	317,31	1960	26	100	1330
	317,91	2120	26	100	1420
	318,45	2240	26	100	1530
	318,98	2400	26	97,3	1680
	319,58	2560	26	60	1740
	320,19	2720	24	60,4	1680
	320,83	2880	24	60,8	1650
	321,37	3080	24	60,8	1580
	321,92	3240	24	62,7	1620
	322,44	3400	25	62	1620
	323,01	3560	25	63,5	1640
	323,59	3680	25	62,7	1670
	324,23	3840	26	64,3	1670
	324,81	4000	26	63,5	1680
	325,37	4200	26	63,5	1640
	325,95	4360	27	60,8	1610
	326,5	4480	27	61,6	1620
	327,05	4600	27	61,2	1610
	327,62	4720	27	59,2	1600
	328,28	4880	27	60,4	1630
	328,81	5000	28	62,7	1620
	329,39	5160	28	63,1	1620
	329,94	5280	29	64,3	1650
	330,44	5400	29	69	1700
	331,03	5520	30	71,4	1710
	331,66	5640	30	81,2	1850
	332,28	5760	30	78	1960
	332,86	5920	32	76,5	1850
	333,45	6040	32	72,9	1850
	334	6160	33	73,3	1760
	334,55	6240	33	64,7	1700
	335,09	6320	33	68,2	1700

2. run in 4.th

	Group A:	'118			
		RPM	Temperature	Load	Absolute Pres,
	TIME				
Marker	STAMP	 /min	°C	%	 mbar
2	375,47	2000	33	0	1010
	376,05	2080	32	100	1060
	376,61	2160	31	100	1210
	377,22	2280	30	99,2	1410
	377,8	2440	29	96,1	1640
	378,36	2640	28	68,6	1730
	378,94	2800	27	62,7	1700
	379,44	2960	27	61,2	1670
	380,01	3080	26	62,7	1640
	380,64	3280	27	64,3	1670
	381,25	3440	27	63,9	1690
	381,83	3640	27	64,7	1690
	382,37	3800	27	66,3	1700
	382,89	4000	27	67,8	1690
	383,44	4120	27	64,3	1700
	384,01	4240	27	61,2	1690
	384,67	4400	28	61,6	1650
	385,3	4560	28	60	1670
	385,84	4720	29	62,7	1630
	386,44	4840	29	62,4	1640
	386,98	5000	29	64,3	1640
	387,48	5120	30	63,9	1670
	388,06	5240	30	64,3	1660
	388,69	5360	30	66,7	1690
	389,28	5480	30	72,5	1720
	389,84	5640	32	77,3	2010
	390,39	5760	33	79,2	1900
	390,86	5840	33	78	1940
	391,44	5960	33	77,6	1900
	392,03	6040	34	68,2	1840
	392,61	6160	35	71	1810
	393,17	6240	36	73,7	1660
	393,75	6360	36	54,1	1710

3. run in 4.th

	Group A:	'118			
		RPM	Temperature	Load	Absolute Pres,
	TIME				
Marker	STAMP	 /min	°C	%	 mbar
3	712,38	1360	33	100	1040
	712,95	1440	32	100	1090
	713,5	1560	30	100	1130
	714,03	1640	30	100	1180
	714,52	1760	29	100	1230
	715,09	1880	29	100	1280
	715,72	2000	28	100	1350
	716,36	2160	27	100	1440
	716,98	2320	27	98,4	1580
	717,5	2520	27	63,9	1770
	718,09	2680	27	66,3	1730
	718,61	2880	27	63,1	1670
	719,16	3040	27	62	1630
	719,75	3200	27	63,1	1660
	720,39	3360	27	64,3	1670
	721	3560	27	66,3	1700
	721,53	3720	27	65,9	1700
	722,13	3880	27	63,9	1700
	722,67	4080	28	64,3	1710
	723,19	4200	28	63,5	1660
	723,78	4360	28	64,7	1650
	724,41	4520	29	63,5	1650
	725	4680	29	62	1620
	725,55	4800	29	65,1	1630
	726,09	4960	29	66,3	1630
	726,59	5080	30	67,5	1650
	727,17	5200	30	68,6	1660
	727,81	5360	30	71,8	1730
	728,44	5480	30	69,8	1740
	729,03	5640	32	80	1900
	729,61	5760	32	79,6	1990
	730,17	5880	33	76,5	1950
	730,67	6000	33	76,1	1920
	731,23	6120	34	70,6	1790
	731,81	6200	34	68,6	1760
	732,48	6320	35	77,6	1750
	733,08	6400	36	64,7	1750

 

[wild willy]

Theres plenty left in the duty cycle of the n75 to make the boost that you would want to make.
The car is pretty much following requested boost. The problem is that the ecu is not requesting anywhere near as much boost as it should be.
At 3200 rpm for example the map should be requesting approx 2450 mb peak, reducing to 2150 mb at red line.
You've put alot of time and effort in trying to fix this, i personally think its a mapping issue. One last thing, i know this is a little daft and i'm sure you are but are you pressing the accelerator all the way down when doing these logs.

Put a link to this thread in the REVO section as its almost as if its reverted back to stock settings. Have you been playing with the sps by any chance and reduced your boost by accident.

 

[Gubien]

Ohhh... sorry not to be clear about this, but this i REVO stock setting. Which means it "basically" request 1850mbar across the whole range...(I've loaded the stock program by a laptop to be 100% sure, and then aquired the setting afterwards)
My goal is to get this working like it should, before switching to the stage1.

The pedal is physically as much a it can down to the floor ( I still think my 78% in block 062 is to little when fully down.(Pedal has been replaced)

 

[Gubien]

small update:

link