I just had a rebuilt P&P&C TD04 installed and it won't boost more than about 14psi. It seems to respond normally but just won't make more than 14psi. My stock TD04 was making about 17 psi before the swap and spooled faster. It's noticeably down on power compared to the stock TD04.

The rebuild was done by a reputable turbo rebuilder and the P&P&C was also from a respected vendor. A professional tuning shop did the install and tried to tune it but gave up. They said no matter what they tried (even tried another wastegate actuator) it would not make more than 14 psi of boost.

Any ideas where to look to solve the problem? I'm thinking the wastegate flapper is not sealing correctly for some reason?

 

how long does it take to build boost?

I would say check the wg arm and flapper. Not loose of nething. But if the shop already looked at all that, it maybe something with the rebuild.

 

Boost builds a little slower than with the original TD04, peaks around 3000-3100rpm vs 2800-2900rpm stock. Still tapers towards redline, the boost control seems to be working, just not getting to where it should.

The tuner checked the wastegate arm and said it felt normal.

 

if tightening the wg didnt do the trick, try swapping out the boost solenoid for another one from another car, see if the solenoids bad. is this a fmic? if so i would have the piping pressure tested

 

if you have a tmic, just check the tmic hose clamps and check hoses for any wear and tear. all of these things can cause your boost problem and all of these things have once happened to me.

 

It's the stock tmic. I removed the intercooler and checked all the hoses and clamps. I've also verified the plumbing to the boost control solinoid. Everything looks good. I think I'm going to try and make a leak tester and see if I can find a leak.

 

I found the problem. I replaced all of the small hoses that connect the turbo to the boost controller. The old hoses were stretched where they went over the barbs and were kind of dried out.

I'm seeing much higher boost than I did with my old td04. I've seen peak boost of about .14 MPa on the stock boost gauge in 3rd gear.

 

That's 20 PSI. Anything past 16.5 PSI in the TD04, ported or not, is wasted air and you're running serious risk of detonation.

 

I got it tuned ASAFP after the boost problem was fixed.

 

^ do you have the dyno sheet>? i'm curious.
thanks
-chris

 

Sorry it took so long to reply.