Only 5Psi Ona 10Psi Tune Wtf, Please Help

[gravelrash]

as the topic says. I have a Xcal2, have had for approx 4 years and never had a problem, always ran the 10psi tune. Now that I have a work car the XR doesnt get driven as much. This morning I started the car and went for a drive, at first I had 7psi but power felt very flat, strange, plugged the Xcal in a reload the 10 psi tune, go for a drive now I get only 5psi. WTF. for sh*ts and giggles I loaded the 8psi tune, same thing 5psi. I have disconnected the battery and reloaded the 10psi tune and still only get 5psi.

I have no vac leaks.

sounds stupid I know, but can a generic tune expire?? it seems as if its gone back to a standard tune.

what wastegate percentage should a 10psi generic tune be set at?

[Forcedfed6]

Possibly be a faulty/sticky boost control valve there.

Try cleaning it... There is a sticky thread in the General tech section on how to do it. Give it a try at least, and let us know how you go with it.

[gravelrash]

thanks Jamie, I was hoping you would answer. that's the one down under the fuse box area isnt it?

How did you go with Brendens car?

[gravelrash]

ok I took the boost solenoid out completely, cleaned it with wd40. something I noticed was the wd40 ran straight through the solenoid and out the other hose barb. is this normal??

also when I put it all back together the solenoid now makes a ticking noise alot similar to the noise of a small air compressor. im guessing this aint right. has anybody got a spare boost solenoid I could try?

[gravelrash]

update: when I reload the stock tune the ticking stops. when I reload the 10psi tune the ticking is back. im thinking this program is software based.

[Ralph Wiggum]

the ticking is due to an increased duty cycle on the boost control solenoid.

Tuners do this to achieve better boost control when the boost pressures are higher than standard.

Nothing to be alarmed at.

The solenoid is inlet/outlet ports are convected.

This directs boost to the actuator.

The actuator is forced open by the boost too maintain a set boost pressure.

The solenoid bleeds boost pressure off to atmosphere when the boost control system becomes active

This allows the spring in the actuator to keep the waste gate closed/less open so that the boost pressure increases.

[gravelrash]

did a bit more playing today.

when I load the valet tune in the buzzing solenoid stops, when I load the factory 5psi tune in the buzzing stops, when I load the 8psi generic tune in the buzzing starts and can only achieve 5psi. when I load the 10psi the buzzing returns and still only achieve 5psi.

so far I have taken the cat off and checked it. its not collapsed, melted or breaking apart.

used compressed air to move the wastegate actuator back and forth hearing it click open and click shut again.

tested for vac/boost leaks.

what I dont understand is I have used these generic tunes out of this Xcal2 for nearly 3 years with no problems, then all of a sudden 5psi only on all tunes.

also I dont understand is how this boost solenoid works, I dont have access to another xr6t to compare.

*thought* if the boost solenoid is faulty would the ecu see that as a fault and peg power and boost back like what it is doing.

*the buzzing noise from this solenoid is so loud my wife could hear it from inside the house.

[nathen]

what was the outcome