BD turbo tuning help...

[AndyL]

New update.... Got the 09 flash on, checked tps at dealer, tore it completely down to the intake boots and it looks great. Took it out again and the same exact thing is still happening. By pass the box again and it runs but it's running in the 20's on air fuel and spits and sputters.
I'm 100% positive the boots are good and the t bodies are mated up perfectly. Took off the air box and put pressure to it and it holds. I'm completely at a loss what to try next, I don't understand why it's so lean and where it's coming from. Going from a 100% dialed setup to this is tough. Any ideas?

 

[Vertical Asshauler]

Did you re-check that the ADA resistor was installed correctly on the TAB sensor wiring?

 

[AndyL]

Boondocker told me not to install that. I'm thinking its an injector issue if its not running right stock now.

 

[Vertical Asshauler]

Did your machine run right before you put this turbo on?

 

[AndyL]

Well I believe I have it figured out.... I checked the injectors and they were perfect. When I bought the kit used the seller said 'ya it ran perfect when I took it off' I assumed everything that I had was in working order. The only thing I haven't tried was switching out the air sensor on the charge tube. I swamped that sensor out with the one on my air box and it runs a lot better. All the issues I had before were gone and I rode down the road and back with no issue. I'm thinking that sensor was bad from the get go and was causing the problems this entire time.... Thanks guys ill report back after Christmas.

 

[AndyL]

check engine light 4 times

New update. Sled runs awesome till 7000 rpm. Right when I hit 7000 check engine shows up and flashes 4 times. I took it to the dealer and they said air box sensor is bad and needs replaced.
Since I just put my original one on there I'm thinking my box is bad and might try replacing it. What baffles me is it didn't flash check engine light with the other sensor when it ran horrible. Hoping a new sensor and a new box will be the end of my troubles.
Also what occurred during the first ride.

 

[philsummers21]

Damn your having hell. Whats up with the exhaust?

 

[AndyL]

It was a slp pipe someone welded up angle iron to hold the halfs together. I was riding the sled back to the truck when a funky noise developed and lost most my power with a a/f of 22.4. I cut the 90 off and welded it up to a stock pipe hoping that was the reasoning of the check engine light, but it wasn't.

 

[Mag]

Are you running an intercooler or the bd airbox? I've got a spare bd turbo airbox laying here.

 

[AndyL]

No I'm not running the inner cooler. It's the old style air box that has the sensor mounting directly into the charge tube. I would be willing to try anything at the moment.

 

[Mag]

The newer kit's have a bypass for that switch. I dont remember if it's just a loop or a resister I cant find my instructions.

 

[AndyL]

Yea the newer kits you zip tie that sensor inside the sled somewhere. Boondocker said I have to put the sensor in the charge tube for my kit.

 

[AndyL]

Spoke to bd today and they said never should the Tmap sensor be in the charge tube... With it being in the tube it's reading the boost pressure and thinking its below sea level causing a check engine light.
I'm going to pull it out and weld up the hole and hope for the best....

 

[AndyL]

It runs! Finally..... Issue I'm having now; I'm only getting 7lbs of boost at 3000' I was getting 5.5 - 6 with everything at O on the ebc. I bumped it up to 10lbs and turned on the altitude compensation and it got me to 7lbs. Is this normal for a pump gas kit? I was having 150-195 on the charge temps too, not real sure what the norm is however it was pretty warm today.

 

[AndyL]

Understanding boost leak

I've been searching the forum for boost leak and can't seem to find a solution. If there's a leak after the the motor in the exhaust would it affect the way it builds boost? I took apart the air box and replaced all the o rings and reinstalled and I'm at a solid 8-8.4 lbs of boost, still can't get 10-12. I took the boots off 2 times and they looked good. Could the actuator be bad? I'm unsure what to try next.

 

[mtnclmr]

I had a similar issue, couldn't get over about 8 lbs. I was pretty sure I had a boost leak but couldn't visually find it. I took the exhaust pipe off the turbo itself and made a cover plate, then plugged the turbo intake and pressurized the whole system. Really the only way to verify for sure there are no leaks. Found that the two little barb/ bolts that hold the aluminium box to the throttle bodies and have the hoses on them were not screwed in far enough giving me the leak.