Na-t overboost and AEM tru boost problem

I'm in desperate need of some help, I'm booked in next week for a remap, it's now the third time and I'm not getting anywhere!

First remap it was struggling to build boost - turned out to be a loose intercooler pipe coupler.

Second remap resulted in overboosting to which I was advised it was my hks copy wg, so I went for the precision pw46 and installed a 4.5psi spring. But I'm still seeing 8.99psi on my aem tru boost gauge/controller that's only at half throttle upto 3500rpm

Upto now Iv tried to disconnect my solenoid and turn off the controller running it straight off the spring but I'm still seeing around 8psi

What else could it be?

What exhaust manifold is it?

Its the Xs power manifold, I know it's not the best

I would be checking the wastegate pipe that goes from the collector, there was a stage where this opening was to small so the boost couldn't be controlled.

Are you also 100% sure you have the boost controller plumbed in correctly?

Sorry had to settle my little boy.

The gauge is plumbed into the t-piece going into the inlet mani:

Bov is plumbed into the t-piece here:

And at the minute the wastegate side port is plumbed straight to the turbo..

Is everything in order?

Why is the brake vac pipe disconnected?

I take it the spring is intended for that specific wg?

You have a decent pipe from the intake side to the wg?

Maybe bypass the boost controller altogether for a test and run a decent size pipe from the turbo pressure side to the wg and see if that stops the boost creep

If not , remove the wg spring so it's effectively gonna be wide open and see if the bypass pipework is capable if flowing enough to stop the turbo over spooling (I doubt at such low pressures this is the problem, usually only occurs nearer 1 bar)

I'd just had the mani off to do my injector resistors, that's why the vac pipe was off.

The springs installed are genuine precision ones and when I pressure tested it it worked perfectly.

Should I have a vacuum hose going from the inlet manifold and T'd into the wastegate?? Because I don't..

When I had the hose going from the turbo compressor to the side port of the wg the gauge stored 8.99psi

Is it plumbed like this?

I had it exactly like this.

Should I have a vacuum feed from the intake manifold to one of the wg hoses?

Just as a test I'd run the pipe from the turbo directly to the wg

If you've pressure tested the wg and it opens at correct psi then if you still have boost creep then it's down to the pipe diameter to the wg not sufficient

Seems like a very odd problem. There aren't any more ports on the boost controller do you? Run the turbo straight to the wg and see what happens. Seems very odd your getting boost creep at that.

Cheers pal that's how I had it on the way home but it made no difference, could a cracked manifold or split vacuum

Hoses have the same affect?

I have the same setup as FOSTA using one of these but on the inside there is a grove where the 2 flanges meet I'm wondering if this could be restricting the exhaust flow?

Its a difficult one because I can't actually push the car hard enough to test it properly so all I can do is gingerly accelerate upto 3500 then check the highest boost stored on the gauge. Now what I'm not sure about is if it was mapped and I was accelerating WOT would the gauge very briefly show let's say 8psi but then flicker around the spring pressure of the wg?

Just a quick update, tried a longer hose straight from the turbo compressor to the wg 5mm silicone hose, but with no luck so next course of action replace the hoses I changed for silicone ones back to stock and check for leaks? Then remove the spring and put in the 1.5psi one.

What map sensor setup do you have?

Stock map T'd into a greddy 3bar?

That's the one pal. Don't think its a genuine Greddy one though? Now for a stupid question what's its purpose

It reads manifold pressure to the ecu which basically determins how much fuel to add

Only reason i ask is when i wired my map sensor wrong on my emanage ultimate, the car ran pig rich and light throttle would send the boost gauge to like 20psi massive overboosting (map sensor wire on the emanage was wired to the temp sensor on oem ecu LOL)

But when it was rectified it ran perfect and has never overboosted

Again i guess its a case of checking the vac hoses to that

Well its something I can look into, thanks! Mine smells like its overfueling sometimes and to make things worst I'm having cold starting issues, takes a few cranks to fire up. I though I'd fixed it with a replacement ignition coil but it's still doing it!

What settings is running on it, just the usual "base" map?

If its emanage ultimate hove you selected the greddy pressure sensor as option 1 in the front panel tab?

It was partially mapped the first time to 0.2bar lol that was when it was struggling to build boost because of a loose intercooler clamp. Then I went back and it started overboosting

Could this be the cause of my problems:

It's the hose going from turbo compressor to intercooler. although it doesn't seem to have split all the way through I'm guessing its defenatly leaking, would that be why my wastegate is not opening?

Have you tried connecting a vacuum line directly from the turbo to the top feed on the wastegate (missing out the controller) ? Not the side feed but top feed?

Can't hurt to give it a go, feel like Iv tried everything else..

I don't know if its contributing to the problem but I'm now wondering if my aem tru boost gauge/controller is faulty too? Since Iv had it Iv never been able to adjust the spr setting lower than 6.9ish psi instructions say to set it 3psi lower than the wastegate spring??

Ive never touched my AEM tru boost gauge/settings so I don't know who to use it lol, I just put the 4.5psi spring set up in the wastegate and took it for a drive and it opend at 4.5psi so I just left it and Ryan turned up the boost by the gauge when he was mapping it so I havnt had the need to touch it lol. So that's the bit I can't really help you with sorry. But I did here of another member that had a faulty solinoid but I don't know how it his was, ican remembeg seeing a few videos on YouTube on how to check to see if its faulty or not by a few tests. Should have alook if your unsure about it working correctly. But first I'd try and get it to open at the correct pressure without the tru boost connected to the wastegate

Hope you get it sorted soon bud!