Helping out a friend with his car....

He took off the manifold, turbo, downpipe and wastegate the other day. Put it all back on with a new Mr. Gasket Copper gasket and put it all back together.

Prior to all this he was running 17-17.5lbs via his AVCR.

Now we put it all back together and he's only running around 13lbs and wont make anymore than that? what gives? we didnt change anything!!!! anyone have any ideas?

things i should check? checked the charge pipes, all look good...checked for leaks or loose bolts at the turbo/manifold/wg and came up with nothing?

we're stumped! we didnt change ANYTHING!!!!

 

???

 

the copper gasket may be the problem....too think to hold boost pressure.....unless you had a copper on before in which case i would just do a boost leak test, vaccum lines, you never know, usually with something like this its the dumbest thing that gets over looked

 

it very well could be the gasket, we had an OEM gasket before and opted to use this one.

its wierd, it almost feels like the AVCR isnt even working, its making about 1bar, which is exactly what the WG spring is. its a tial WG and it has one vac fitting on the top port and one on the side. we used the supplied fittings but one is longer than the other by about an 1/8th inch? perhaps we had them switched?

we'll hopefully have more updates tonite.

 

Update:

Took off the old Mr. Gasket Gasket....replaced it with the stock gasket, this made no difference.

we took out the car, it felt like it was running off the wastegate??! prior to taking off the manifold as I stated the car was running about 17-17.5lbs. Now it was reading consistently .96bar on the AVCR, even though the AVCR was set at 1.3bar. upped the duty and it the boost came up a bit.

Now we have the AVCR set to 1.6 bar with a 75% duty and its making about 1.15 bar. What gives? prior to this we never adjusted the AVCR at ALL! we're so confused. any ideas? pulls a perfect vaccuum still. no boost leaks, nothing was changed at ALL!!! we took the manifold off, put it back on and now we're way down on boost. the car is running a boost cut at 18lbs so im not worried about over boosting, but with the AVCR set to 1.6 bar why is it only making 1.1 bar actual?

 

????

 

did you check the vacuum lines going into the boost valve
and the lines running into the wastegate?

 

sounds like a leak somewhere, I too had a leak I never knew about, found it pluged it and gained 5 psi and 400rpm spool difference.

 

No leaks that i can see or hear. no exhaust leaks that i can see or hear.

there were no leaks prior to taking off the manifold and everything was fine! this is waht stumps us the most. it was running fine, the manifold cracked so we took it off, re-welded it, put it back on and now we're having issues! (WHAT GIVES!)

Ill re-check allllllll the vac lines..... its pulling good vac though, 18-20" of merc at idle!

 

bump

 

this sounds like what happened to my friends evo. boost conroller wasnt working and he was peakin at like 14 psi. turned out it was his utec. with this in mind...what ecu do u have in there, what is your ca rtuned with and by who....etc. try swappin out the ecu for another, try totally diconnecting the avcr and just run wastegate and see if it will hold that amount of boost using a mechanical boost gauge.
good luck