GROUNDED - Starting an EJ205 Rebuild - Page 3 - Subaru WRX Forum
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post #31 of 55 Old 09-08-2014, 08:34 AM Thread Starter
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Not getting full boost though, as the Stage 2 specs for COBB's OTS 91 Octane map are: Boost Target: ~16.5psi peak boost pressure tapering down to ~12.0psi by the 7250RPM redline, +/- 1.0 psi



So there is still some work to do. My Subaru mechanic noted this lack of full boost pressure in his shakedown runs after the intercooler work, and suggested it might be because the turbo is getting tired.

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post #32 of 55 Old 09-08-2014, 02:34 PM
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Hmmmmm....How is your vacuum?

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post #33 of 55 Old 09-08-2014, 05:00 PM Thread Starter
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Not sure what to look for Kieth in the vacuum, but I could send you the log if you PM me an E-mail address. Otherwise, let me know and I'll go through the log and let you know.

We're planning to isolate the boost controller and momentarily let the turbo produce maximum boost, to confirm whether it's a controller issue. Replacing a controller's likely cheaper, and I've heard that the OEM boost controllers may not be reliable when dialing the boost up like I'm trying to do.

He suspects the turbo may no longer be able to produce 16.5psi boost [+/- 1.0psi], which means rebuild or replacement. This is not so cheap.

I just want it to produce the rated 16.5psi boost, is all.

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post #34 of 55 Old 09-08-2014, 06:44 PM
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I dont think I ever got past 16.0psi on my TD04, then again it did have 150k miles on it.
Most of the time I would adv. 15.5 on stage 2 93oct.

Hopefully you get it sorted out, it does suck having to hunt down leaks and such.
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post #35 of 55 Old 09-08-2014, 07:24 PM
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Easy way to test is to unplug the line and let it produce wastegate pressure boost rather than risk over boosting and nuking a nice new motor...You should be running between 21-17 In/Hg of vacuum by the way...Could have sworn Cobb's target boost was 18psi on a Stg. 2 map....
p.s. I have a spare compressor side of a turbo in my garage...

p.s.s. I am surprised you didn't say something like, "My vacuum works great, it's a Dyson." just to be silly.
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post #36 of 55 Old 09-08-2014, 08:00 PM Thread Starter
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Kieth,
Might you have rebuit a TD04 before? In case I need that. Ha ha.

Chuck,
Tinkering and investigations can be fun, as long as your not stranded...

It's running fine, no codes, I enjoyed it at the track - so thankfull no urgency and no anxiety.

I also know that it's a 10 year old vehicle, and parts are going to get tired and will need to be replaced. So some of this I expect.

The turbo inlet pipe is one of those items, so I've been eyeing a Perrin item instead of an OEM replacement.







However, addressing the issues preventing achieving rated boost will be first.

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Last edited by LW_Black4; 09-08-2014 at 08:36 PM. Reason: add image
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post #37 of 55 Old 09-08-2014, 08:53 PM
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I have rebuild them, but I have the compressor side that you'd need to get back to factory spec... My prices are INSANE!!!!
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post #38 of 55 Old 09-08-2014, 09:12 PM Thread Starter
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I'll take you up on your offer Kieth.

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post #39 of 55 Old 09-08-2014, 10:13 PM
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Quote:
Originally Posted by LW_Black4 View Post

I also know that it's a 10 year old vehicle, and parts are going to get tired and will need to be replaced. So some of this I expect.

The turbo inlet pipe is one of those items, so I've been eyeing a Perrin item instead of an OEM replacement.
I have the perrin inlet and like it but, wish I had gone with a hard inlet. Just a word of advice in hindsight. I also have a spare stocker if needed

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post #40 of 55 Old 09-09-2014, 08:11 AM
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18lbs of boost at stage 2!
Man have I been missing out, dam my TD04.

Also have a perrin inlet and honestly think they are over rated.
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post #41 of 55 Old 09-09-2014, 10:58 AM Thread Starter
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Thanks for the offers, gents. let's first find out what we need.

Here's what I'm using for target boost levels:

COBB v310 Map Notes for 2002 - 2005 WRX

Stage2 Maps
 Stage2 ACN91 v310
o Fuel Requirements: 91 octane fuel found in Arizona, California, and Nevada or better
o Intake Requirements: Stock airbox or COBB Tuning SF Intake
o Exhaust Requirements: Upgraded turbo-back exhaust
o Boost Targets: ~16.0psi peak boost pressure tapering down to ~12.0psi by the 7250RPM redline, +/- 1.0 psi
 Stage2 91 v310
o Fuel Requirements: 91 - 92 octane or better
o Intake Requirements: Stock airbox or COBB Tuning SF Intake
o Exhaust Requirements: Upgraded turbo-back exhaust
o Boost Targets: ~16.5psi peak boost pressure tapering down to ~12.0psi by the 7250RPM redline, +/- 1.0 psi

 Stage2 93 v310
o Fuel Requirements: 93 - 94 octane or better
o Intake Requirements: Stock airbox or COBB Tuning SF Intake
o Exhaust Requirements: Upgraded turbo-back exhaust
o Boost Targets: ~17.0psi peak boost pressure tapering down to ~12.0psi by the 7250RPM redline, +/- 1.0 psi

And look what I found in the notes that makes sense:

Monitoring Boost Levels:
The best way to determine if you are hitting target boost is to watch the TD Boost Error parameter. This parameter is your target boost (including altitude and temperature compensations) minus your actual boost (negative values mean you are over the target by the amount while positive values mean you are under). Ideally you want this value to be between 0 and 1.0 at wide open throttle (WOT), but -1.0 to 1.0 is acceptable assuming that you don’t have any significant knock corrections. Overboosting is more likely to occur in higher gears and with colder outside temperatures, so be sure to verify boost levels during these conditions.

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post #42 of 55 Old 09-09-2014, 11:26 AM Thread Starter
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Any experience good or bad with COBB Tuning's 3-Port EBCS controller? I like that it's compatible with the OTS maps.

Yes I know, I should go for a protune. However, I'm still committed to keeping the hardware compatible with the OTS maps, and this upgrade is compatible.

Also, their OTS maps are improving and more refined now. Still safe, but more refined.



Cobb Tuning 3-Port Ebcs - 2002-2007 Subaru Wrx - 712750 - Boost Control & Wastegates - Turbo

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Last edited by LW_Black4; 09-09-2014 at 11:28 AM. Reason: OTS maps evo
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post #43 of 55 Old 09-09-2014, 02:13 PM
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I'd stick with what you have unless the factory boost controller is bad. I've been away from Cobb's stuff for to long and my read up on it a bit. If you are interested in that compressor shoot me a PM and we can figure out shipping etc. You can replace the inlet while doing the compressor replacement...Best of all you won't have to take the damn exhaust loose to fix it...

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post #44 of 55 Old 09-10-2014, 12:17 PM Thread Starter
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Better datalog last night.

Seeing max boost of 15.24psi this time, when target is 16.5ps +/- 1.0psi. Scared to bounce the new motor off the rev limiter, but peak boost is at 5500rpm anyway.

Boost correction is 2-3psi in the log at WOT, so we're still doing some diagnostics. We'll check out the vacuum lines and boost controller to see if they are holding back the turbo in any way, and then we'll go from there.

Either way, it's an acceptable result because the turbo is at 250,000km.


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post #45 of 55 Old 09-10-2014, 08:10 PM
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Quote:
Originally Posted by LW_Black4 View Post
Kieth,
Might you have rebuit a TD04 before? In case I need that. Ha ha.

Chuck,
Tinkering and investigations can be fun, as long as your not stranded...

It's running fine, no codes, I enjoyed it at the track - so thankfull no urgency and no anxiety.

I also know that it's a 10 year old vehicle, and parts are going to get tired and will need to be replaced. So some of this I expect.

The turbo inlet pipe is one of those items, so I've been eyeing a Perrin item instead of an OEM replacement.







However, addressing the issues preventing achieving rated boost will be first.
I'll be selling my black Perrin silicone turbo inlet in the very near future if you're interested in saving a few bucks on a used one
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