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Old 06-28-2013, 01:16 AM   #1
OBP WRX
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Default flat spot from 3200-4500 rpm

2005 WRX went from stage 2 protune to Blouch Evo 3 16g and DW 750cc and getting an e-tune.

During 3rd gear WOT pulls the car builds boost until 3200 rpms and then it drops 1 psi and then slowly recovers to where it was at 3200 rpm around 4500 rpm and then keeps building until redline.

I have done boost leak tests and leak down tests and both are good to go. The turbo was bought used off the forum. Previous owner had EWG and I am using IWG. I adjusted the preload and I build more boost, but still has the same drop in the same spot.

Tuner says it is mechanical, any ideas? I am out of money and running out of patience. I have been hitting up the local subie guys for help, but wanted to cast a wider net as well.

Thank you
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Old 06-28-2013, 01:40 AM   #2
super_usdm
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What psi does it stop building at? What was the intake pressurized to during the boost test? What boost control solenoid are you using? What bpv are you using?
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Old 06-28-2013, 03:59 AM   #3
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Intake was pressurized to 20 psi. I have a MAC 3 port EBCS and stock BPV.

2005 WRX w/ 88K miles on it. Cobb SR intake, Perrin turbo inlet, blouch evo 3 16g, GrimmSpeed TMIC, MAC 3 port EBCS, invidia catless DP, 3" exhaust, GrimmSpeed catless UP (coated), Fresh NGK iridium plugs stock heat range, DW 750cc injectors.

3rd gear WOT log from AP (no dedicated wideband)

Time (AFR) Boost Timing MAF V RPM Throttle mph WG duty
209.48 13.32 -7.54 40 2 2572 9.02 34.8 0
209.74 13.55 -7.56 40 2 2578 9.02 34.8 0
210.02 13.55 -7.56 40 2 2573 9.02 34.8 0
210.28 13.44 -7.58 40 2 2573 9.41 34.8 0
210.58 12.06 -1.26 28.5 2.6 2641 32.16 35.42 10.59
210.84 11.6 0.97 22 2.72 2634 67.06 36.04 24.31
211.11 11.37 2.01 20 2.72 2680 83.92 36.04 38.43
211.38 13.9 3 19 2.8 2771 93.33 36.66 52.55
211.68 14.13 4.14 16.5 2.96 2820 96.08 36.66 69.8
211.94 13.09 5.32 15 3 2905 100 37.9 83.92
212.21 12.86 6.56 13.5 3.12 2983 100 38.53 85.1
212.51 13.32 8.18 12.5 3.2 3056 100 38.53 82.35
212.79 13.55 9.61 11 3.28 3131 100 40.39 79.61
213.05 13.67 10.07 11 3.26 3252 100 40.39 78.82
213.33 12.98 9.44 11.5 3.34 3319 100 42.25 79.61
213.61 13.21 9.15 12 3.38 3389 100 42.25 81.18
213.87 13.44 9.22 12 3.38 3481 100 44.12 82.35
214.15 14.01 9.44 12 3.4 3602 100 45.98 83.53
214.41 13.9 9.32 12.5 3.38 3674 100 45.98 83.53
214.67 14.24 9.32 13 3.48 3774 100 48.47 83.53
214.95 13.9 9.09 13.5 3.48 3842 100 48.47 83.53
215.23 13.55 9.15 14.5 3.46 3963 100 50.95 83.53
215.49 11.6 9.18 15 3.5 4012 100 50.95 83.14
215.77 11.14 9.3 15 3.56 4105 100 52.82 82.75
216.03 11.14 9.26 15.5 3.54 4206 100 54.68 81.96
216.31 11.14 9.48 15 3.62 4332 100 54.68 81.57
216.57 11.14 9.77 14 3.68 4385 100 57.17 80.78
216.85 11.14 10 14 3.74 4517 100 57.17 80.39
217.13 11.14 10.23 14 3.76 4658 100 59.65 79.61
217.39 11.14 10.48 14.5 3.78 4719 100 59.65 78.82
217.67 11.14 10.35 14.5 3.82 4835 100 62.14 78.04
217.93 11.14 10.46 15 3.84 4895 100 64 77.25
218.19 11.14 10.81 15 3.9 5033 100 64 75.69
218.47 11.14 11.37 15.5 3.96 5105 100 66.49 74.51
218.75 11.14 12.26 15 4.06 5259 100 66.49 71.76
219.01 11.14 13.36 14.5 4.14 5345 100 68.97 66.67
219.29 11.14 14.56 14 4.22 5446 100 72.08 62.75
219.57 11.14 15.84 14 4.3 5584 100 72.08 58.82
219.83 11.14 17.09 13.5 4.36 5703 100 75.19 56.86
220.11 11.14 18.1 13.5 4.42 5836 100 75.19 52.55
220.39 11.14 18.51 14 4.44 6028 100 77.67 43.53
220.65 11.14 18.68 14 4.48 6092 100 77.67 36.86
220.93 11.14 18.8 16.5 4.5 6281 100 80.78 26.67
221.19 11.14 18.85 16.5 4.52 6382 100 83.26 15.69
221.47 11.14 18.95 16.5 4.56 6499 100 83.26 8.63
221.75 11.14 18.97 16.5 4.54 6544 100 86.37 0
222.01 11.14 18.87 16.5 4.54 6684 100 86.37 0
222.27 11.14 18.83 17 4.54 6830 100 88.86 0
222.57 11.14 18.89 17.5 4.54 6918 80 88.86 0
222.83 11.48 -10.52 11.5 1.64 6573 0 92.58 0
223.11 11.25 -12.03 11.5 1.08 6067 0 93.83 0
223.37 11.48 -12.39 11.5 1.32 5490 0 93.83 0
223.64 13.78 -12.39 11.5 1.28 4947 0 95.07 0

I thought it was tune related (some sort of safety deal until we got it more dialed in) but my e-tuner tells me it is mechanical. I have the same 1 psi drop in every log in the same range 3200 to 4200-4500 rpm...it slowly tapers 1 psi and then slowly comes back up 1 psi. Other than that the car feels pretty good. Sometimes in needs an extra second or two cranking to start (DW Injectors) and I am resetting my ECU with every new map, so the comp isn't able to learn and fine tune the AFR and timing.
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Old 06-28-2013, 08:35 AM   #4
ToddMcF2002
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Call Blouch. They open around 7:30AM and they could likely give you a few leads on what might be wrong. It sure sounds mechanical. The basic rebuild is only around $300 and that's a great turbo...

BTW very nice mod list
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Old 06-28-2013, 11:13 AM   #5
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Thank you. Tuner tried another map this morning...I installed and logged and still same flat spot from 3200-4500. Normal driving it pulls hard...and normally I wouldn't be going WOT from 2500 RPM in 3rd, so it wouldn't affect me too much, but I still would rather it be fixed and fixed correct. Gonna try to call Blouch now.
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Old 06-28-2013, 11:43 AM   #6
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Just called...they are on summer vacation until 8 July. Hoping the turbo doesn't need a rebuild and it is something simpler and cheaper (actuator, EBCS, or the upstream O2)
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Old 06-28-2013, 12:56 PM   #7
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Its not turbo seals or bearings so dont waste yor money on a rebuild. Your wastegate opening too much too early could cause the boost to fall flat in lower rpms like in your log. Do you know what size spring is in the actuator? If you have a 1 bar spring in there you will be able to isolate your problem by running the boost feed directly to the actuator.

A failed 02 sensor would throw a CEL. I assume no codes?
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Old 06-28-2013, 04:32 PM   #8
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a one psi change is not that much. your internal wastegate could be sticking.
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Old 06-28-2013, 04:37 PM   #9
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Quote:
Originally Posted by mcpoevo View Post
a one psi change is not that much. your internal wastegate could be sticking.
Sticking would cause over boost. Bye.
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Old 06-29-2013, 12:26 PM   #10
OBP WRX
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I pulled the actuator off my TD04 and swapped them out and same thing. It builds boost and then loses boost and then climbs back slowly and then takes off. If I didn't have the logs to look at I would just say it is laggy as hell.
Part throttle response is not bad, it is just when I go WOT it starts has this huge delay...

I thought WG might not be sealing but I think that would look different.

My tuner had me remove the line going from my EBCS to the actuator and run a 3rd gear 3-4K WOT pull and it (time....Boost....MAF V.....RPM)

5.76 2.17 2.54 2057
6.02 2.32 2.56 2099
6.30 2.46 2.56 2173
6.56 2.59 2.60 2215
6.86 2.75 2.62 2271
7.14 2.92 2.64 2328
7.40 3.13 2.66 2364
7.68 3.36 2.72 2448
7.96 3.67 2.78 2526
8.22 4.02 2.78 2573
8.50 4.39 2.82 2624
8.78 4.72 2.84 2699
9.04 5.16 2.90 2735
9.32 5.80 3.02 2842
9.60 6.61 3.08 2902
9.86 7.68 3.20 2919
10.13 8.86 3.20 3054
10.43 10.35 3.32 3115
10.69 12.07 3.44 3199
10.97 14.27 3.60 3276
11.25 17.19 3.74 3435
11.51 20.59 3.96 3499
11.79 22.82 3.98 3676
12.05 23.46 4.02 3810
12.32 23.55 4.10 3945

It has to be either the MAC EBCS (picked up a MBC last night just in case), a faulty sensor, or something in the tune...something is outside of parameters and then has to be why it is getting dialed back once I got WOT. I am wondering if changing the hose size from the EBCS to the actuator and/or compressor outlet will help.
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Old 06-29-2013, 03:33 PM   #11
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My money is on faulty BCS.
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Old 06-29-2013, 05:57 PM   #12
OBP WRX
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I think so too. It is a MAC. I picked up a GrimmSpeed MBC last night (somebody local had one for sale or I would have got the GS EBCS), but haven't installed waiting for my tuner to get back to me. Might end up buying the GS EBCS anyway depending on what the tuner says...

The only other thing I can think of is some sensor is going out that the computer uses to calculate some important ****.

Will post back when we get it resolved. I appreciate the help troubleshooting. I think the car will be pretty quick once we get this issues resolved and tuned properly.
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Old 06-29-2013, 07:07 PM   #13
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perhaps clean your maf sensor?
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Old 06-29-2013, 10:11 PM   #14
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Quote:
Originally Posted by OBP WRX View Post
I think so too. It is a MAC. I picked up a GrimmSpeed MBC last night (somebody local had one for sale or I would have got the GS EBCS), but haven't installed waiting for my tuner to get back to me. Might end up buying the GS EBCS anyway depending on what the tuner says...

The only other thing I can think of is some sensor is going out that the computer uses to calculate some important ****.

Will post back when we get it resolved. I appreciate the help troubleshooting. I think the car will be pretty quick once we get this issues resolved and tuned properly.
Sounds like it'll be a fun car. Ill be checking back. Good luck!
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Old 06-30-2013, 02:01 AM   #15
OBP WRX
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Think I got it fixed. Put on the MBC and it boosted fast and hard... took off the MBC and went to hook EBCS back up and noticed a tear in the hose right before at the EBCS nipple...cut that part off and reinstalled and it went back to doing the same thing. Came home and double checked the plumbing of the EBCS and when I put it back together, I put it back wrong, so I switched the lines and now it hits 20+ psi by 3300 rpm and then bounces all over the place because it is over boosting. Tomorrow I am going to take some pre-load out the WG arm and get it so it is peaking around 18 psi and then reset the ECU and let the computer and my tuner sort out the details.
Makes me wonder if it was the tear or if the lines were backwards the whole time. I know I went out and double checked them...oh well, as long as it works now

Know anybody who wants to buy a VERY gently used GS MBC?
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Old 07-10-2013, 03:48 AM   #16
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Glad to hear you got it worked out. I'm sure that GS bcs will go quick if you throw it up in the classifieds.
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