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I'm working on a calibration for a Baja Turbo (A2WC501L) and am having a problem with the WGD%. Any time I alter the Initial & Max wastegate duty cycles, I can do everything but get the WG to reach a full 100% duty. It maxes out at exactly 90.2% every single time. I can even change the Initial WGD and Max WGD to 100% in every single cell, and the car will still max out at 90.2% on my logs.

Anyone have any idea what i'm missing here?

EDIT: Here is a logggg....

your WG solenoid is being protected from overheating and sticking, probably.
you know you aren't supposed to run over 90%, right?

05GarnetLGT wrote:your WG solenoid is being protected from overheating and sticking, probably.
you know you aren't supposed to run over 90%, right?

It's completely normal for boost control solenoids to be run at 0% (idle and cruise) and 100% (spool up). It would take a LOT to make a BCS to overheat.

x99percent wrote:It's completely normal for boost control solenoids to be run at 0% (idle and cruise) and 100% (spool up). It would take a LOT to make a BCS to overheat.

exactly. And it can be done easily on all other subarus. for some reason it is like this one is "clipping" at 90.2% even though the map was changed to 100%.

Also, judging from the log, something is wrong with this car. It didn't even make 11psi.

x99percent wrote:

05GarnetLGT wrote:your WG solenoid is being protected from overheating and sticking, probably.
you know you aren't supposed to run over 90%, right?

It's completely normal for boost control solenoids to be run at 0% (idle and cruise) and 100% (spool up). It would take a LOT to make a BCS to overheat.

Im just going by what cobb says in the streettuner PDF.
just like a fuel-cooled injector isnt supposed to be run 100%DC

05GarnetLGT wrote:

x99percent wrote:

05GarnetLGT wrote:your WG solenoid is being protected from overheating and sticking, probably.
you know you aren't supposed to run over 90%, right?

It's completely normal for boost control solenoids to be run at 0% (idle and cruise) and 100% (spool up). It would take a LOT to make a BCS to overheat.

Im just going by what cobb says in the streettuner PDF.
just like a fuel-cooled injector isnt supposed to be run 100%DC

Then you get to tell companies like TurboXS and Apex'i that they have it all wrong.

05GarnetLGT wrote:Im just going by what cobb says in the streettuner PDF.

Yeah, just remember that Cobb is the same people that state that the OEM ecu is only good for 100 flashes... just to make the AP "Realtime" map technology seem better and attract more customers away from EcuTek.

Take everything with a grain of salt my friend... it's not all as black and white as they make it seem.

have you also zeroed out all of the WG duty compensation tables. Also if you boost target is reached it wont get to 100% WG duty even if thats all you have in the table

mattims wrote:have you also zeroed out all of the WG duty compensation tables. Also if you boost target is reached it wont get to 100% WG duty even if thats all you have in the table

I can set the boost target to something retardedly high, and set the wastegate duty to 100% all across the map, and it still maxes out at 90.2% exactly. Like something is limiting it. It does this on the stock calibration as well. I'm almost beginning to think that something is wrong with the solenoid. Swapping it out would be one of my next steps.

I have not played around with any of the WG duty compensation tables. What are these tables you speak of? And what do I set them to? 1.00? or 0?

i think this might be the problem then.

I have an intake temp calibration,
atmo pressure
Gear (seems to be only the twin turbos that have this and maybe sti's)

these can add or remove upto 40% of WG duty.

i would imagine even if the solenoid was broken that it would still read the desired duty cycle.

Also, check your max wastegate duty table. Set the initial wastegate duty table just below where it needs to be, and set the max duty table accordingly, to take into account changing conditions.

yes i have done that. It does not matter what I set max & initial to. It still will not go above 90.2% .,.. I believe there might be a map I am missing somewhere.

the fact that you are only getting 11psi seems odd. Have you checked the WG actuator arm to make sure it is not loose?

I think you should go back to the stock map and datalog for a bit, see if you are able to hit factory set boost levels. If not, quit messing with random tables until you get the car working correctly. =)

Factory boost on this car is only 11.6 psi. MAX. If you look at the STOCK WGDC tables that is achieved mid range with a 90% WGDC.

This car will hit 11.6 psi on the stock map and this map. It will go no more than that. the wastegate arm is definatly tight and from the factory set with quite a bit more preload on the spring that other td04 cars like a wrx. there are only a few threads left before the nut bottoms out.

Even if the WGDC could achieve 100% (which is still strange it is not) I dont think you would see much more boost. I am thinking that this car possily has a lighter spring in the wategate actuator than other TD04s.

Either way, the point of this is that the car will not go above 90.2% duty cycle even though more is being requested. Whats up with that?