Less boost when cold?

[schmoplerator]

This might be a little lengthy but bear with me please, I'm at a loss of ideas right now. So at the start of this winter I started essentially a stage 3 "build". I've installed so far, Swift Springs, MAP intercooler, MAP charge pipes with a turbosmart veeport pro BOV, BOV reference adaptor to link intake manifold to BOV, MAP BPV block off plate, BPV dummy connector, MAP catback exhaust, Cobb DP, and AP3. Also when I purchased the car there was a catch can already installed. The car gets parked for the winter because I live in MN and have another daily. but after installing all of the parts I wanted to take it out just to ensure that everything was working as it should, gladly I did because what came of it was I found out that I had an odd boost issue. The first mini pull I did I peaked 18psi. after my next pull I had NOTHING. After fixing little boost leaks I'm back up to and average of 7psi. NOW, I have done countless pressure tests, multiple smoke tests and tried spraying soapy water on everything, now all I have to show is a fiesta that still has low boost and now a seeping oil pan gasket (too much pressure when performing the smoke test) derp. Most recently I went to a buddies to do another smoke test and nothing came of it, I wanted to show him the loss of power so we took the car out. I peaked 18 psi on my first attempt of a pull. After that it gradually went down pull by pull to my previously stated average. Here's the difference between working in his garage and mine. His is heated. I swapped the factory BPV back on and there was no difference. I installed a new BOV warming it up with a heat gun before installation (same turbosmart, just another new one), and peaked around 9psi on my first pull and slowly went back to 7. I am getting a WGDC of 70-71 on my stage 3 OTS tune. I'm truly at a loss of ideas and have no idea where to go next. I've been turning wrench for years and used to be ASE certified (gave up my "dream" of being a technician), I took my time doing everything. Now I am asking my fellow brothers, does anyone have any educated advice? Thank you to all who took the time to read.

 

[TyphoonFiST]

Put everything back to stock....except the intercooler and charge pipes. Then go from there....

 

[PunkST]

Check your block off plate first. I had a loose bolt on my cpe one for months without realizing it wasnt sealing all the way. If need be put the stock DV and cold side charge pipe back on to at least rule out that.

 

[PunkST]

Also does that bov need to be adjusted in any way?? You could be overpowering the diaphragm in it if its not adjusted right and dumping pretty much everything. i lost a meth port block off stud once and was stuck at 14 psi all winter.. Lol. So check for that as well if it had one.

 

[schmoplerator]

I put stock bpv back on but didn't plug it in, I left the dummy connector on, tomorrow I will plug it in and see what happens. Factory cold side charge pipe is kind of a no go as of now as to I threw the symposer away. BOV was set as directed, tighten until it no longer stutters after revving engine up and does not flutter. I just tested my wastegate, it started opening at 5psi and was fully open at 8 psi.

 

[PunkST]

Lines to your controller hooked up right? Nothing missing or torn?

 

[schmoplerator]

As far as I know, car boosted fine before this winter and I never touched any lines to or from the solenoid or actuator until now. I don't believe anything is torn or I should have saw it when I was doing my smoke tests.

 

[PunkST]

Hmmm. Its wild that it keeps dropping pressure.

 

[schmoplerator]

Yeah I think like Typhoon said I'm going to have too start swapping OE parts back on and start seeing what happens. Still would love to hear other ideas. Thanks for the input.

 

[PunkST]

Let us know what you find.

 

[CarGuy]

Could it possibly be the tune?

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[JDG]

Could it possibly be the tune?

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Surprised it took 11 posts for this to get mentioned. You never mentioned what tune you are running? Post up a datalog. It will be immediately obvious what the issue is after you do this and we get a chance to look at the log.

 

[schmoplerator]

I am currently on stage 3 ots tune, I will try switching maps and see what happens, last time I did it had virtually no change. What parameters should I be logging?

 

[JDG]

I am currently on stage 3 ots tune, I will try switching maps and see what happens, last time I did it had virtually no change. What parameters should I be logging?

Fiesta ST Big Turbo Logging Parameters:

- (C) WGDC Base
- Accel Pedal Position
- Actual AFR
- Airflow Mass
- Boost Pressure
- Charge Air Temp.
- Coolant Temp.
- ETC Angle Actual
- Engine RPM
- FRP Actual
- Ign Corr. Cyl1
- Ign Corr. Cyl2
- Ign Corr. Cyl3
- Ign Corr. Cyl4
- Ign Timing Cyl3
- Load Actual
- Lowside FP Actual
- LTFT
- Oct Adj Ratio Lrn
- Knock Count cyl 1
- Knock Count cyl 2
- Knock Count cyl 3
- Knock Count cyl 4
- STFT
- TIP Actual Absolute
- Turbo MFRACT Desired
- Turbo PID I-Term
- Turbo PID P-Term
- VCT Intake Angle Actual
- VCT Exhaust Angle Actual
- WGDC Actual

 

[schmoplerator]

https://datazap.me/u/schmoplerator/stage-3-91?log=0&data=6-10
https://datazap.me/u/schmoplerator/stage-2-91?log=0&data=6-10
pulled turbo inlet tube and felt for shaft play in the turbo, got nothing. Reconnected bpv connector and did 2 3rd gear data logs. at 4200 rpm in stage 2 log the car absolutely fell on its face. Let me know what you guys think or If you want them in a different format.