Error Codes, Overboosting, Exhaust Howl, Pulled Turbo Off And Cant Fin

[JamieB]

Hi,

Ive got an array of problems with my xr6t, It is an Auto BA with 200,xxxKM.

Factory with only turbo back ss X-force exhaust and I am about to bolt a wog style front mount on.

Whenever I am under any throttle I can hear a 'wizzing' sound that I have heard previously with boost leaks however I cannot find one. (Have pulled crossover off and checked tb joiner.

when under Hard acceleration and high in the rev range it also makes a 'howling' noise from the exhaust. I was told this is likely boost leak on the exhaust side, so I previously pulled the turbo and manifold off, installed new studs and gaskets and reassembled, this did not fix the problem.

I have a mate with a laptop setup with VCM editor and some diagnostic software, we unlocked my ECM and found the following codes: (We are also able to do any ecm edits necessary)

P0236 - TC boost system

P0238 - TC Boost sensor circuit high voltage

P0243 - Turbocharger wastegate solenoid 1

P1183 - Engine oil Temperature Sensor Circuit

P1227 - Wastegate Failure closed (Over pressure)
P2105 - Throttle Actuator Control System - Forced engine shutdown

So I have once again pulled the turbo off and had a decent inspection but cannot find what I would think to cause these problems. The turbo has only slight amount of in/out movement (an amount I would conciser allowable, but I can measure with dial gauge if necessary) and there is no evidence of the impeller contacting the housing. It was also still making boost (to the point of over boost) so I am hoping turbo health is still good. The only problem I can see is a slight crack around where the rod goes to the flapper, but I don't think its possible for it to be leaking from here? I have also heard the flappers do not open sufficiently but is this really the maximum amount of travel for a unmodified flapper?

Is there a DIY I can do to increase the flow of the wastegate flapper without having to send the housing away? (Car is daily, need it on the road ASAP)

I was also going to replace the boost solenoid, but have been unable to find one on the net, and my local ford dealer are not too helpful. also how does the Solenoid bleed off boost to the wastegate if the bottom port is capped?

Thanks for any assistance

[sexual harrassment panda]

turbo back exhaust may cause overboost, if you have a dicky actuator or solenoid then this could be a recipe for a rebuild.

[JamieB]

how would one test the actuator? by blowing air directly into it and seeing if it opens?

obviously there is more than just over boost going on though? If I was to give it an edit to accept another ~2psi could this compensate for the overboost? How much boost is 'safe'? for daily with standard injectors?

[sexual harrassment panda]

yeah compressed air a tap and a pressure gauge, check what pressure the actuator cracks at.

could also run the boost line from the compressor housing to the actuator directly to rule out the actuator.

Do you have a boost gauge?

[ratter]

if you can't afford to have the car off the road for a day or 2 how are you going to manage if the engine grenades?

What does your mate with the software say?

if you are going to trust him to alter the tune then trust what he says is wrong with it as your engine is in his hands

[JamieB]

me and my mate are both heavy diesel mechanics so we have mechanical knowledge, just not 100% relateable to this application.

My mate with the software says 'if it grenades its on me (him)'

I have an ultra gauge which was previously seeing upto 10psi then cutting power, but it was very intermittent - it would do it one day but not the next, which is why I was thinking actuator problem

[ratter]

you need to adjust the tune to suit the exhaust and don't waste your time with that cooler

[JamieB]

Thanks, I should state the exhaust was on the car when I bought it so I can't be sure if it has been tuned, but I'm thinking not. Does the tune need to be edited because the waste gate cannot handle the extra flow?

[ratter]

Any changes to the car pretty much need a tune

[FiftyOne]

Retune it