Damond tuning process Over-Boosting

[philip B]

HI!…says nobody.
I’m slightly new to this forum and only been modding my cars since 4 years ago when I really got into it so limited on knowledge in cars but know the basics.

Mazdaspeed 3 2012 bought from CarMax bone stock @70k miles
Current mileage 95k this is a weekend car. I have 4 vehicles
Mods-( stock everything except what’s listed below)

.Grimmspeed EBCS 3 port mode.

.Injectors Cleaned by RX injectors before tuning process began.

.Valves soaked and cleaned with b12 and vaccumed before tubing began.

3" Exhaust Cat back titanium tips -ULTIMATERACING

. EGR Delete w/ block of plate -DAMONDMOTORSPORTS

. Oil Catch Can vta- DAMONDMOTORSPORT

. High-pressure Fuel Pump Internals/e85 gasket kit combo -CORKSPORT

. Spark plug replaced/ LTR6BHX .26 gap -AUTOZONE

. Turbo Oil Restrictor bolt -DAMONDMOTORSPORTS

.PCV plate upgrade -DAMONDMOTORSPORTS

. Rear motor mount -DAMONDMOTORSPORTS

. Dual VTA Bypass Valve -CORKSPORT

. 3.5” Downpipe cat-less -CORKSPORT

. 3.5-inch Mazdaspeed 3 Power Series Intake System -CORKSPORT

. TMIC Top Mount Intercooler -CORKSPORT

.VCTS deleted completely plugged intake manifold hole.

.Software using Versatuner.

.oil pennzoil 5w-30

.Corksport injector seals installed

.Compression 180,180,175,180 after new seals

PROBLEM- OVERBOOSTING 22+ psi resulting in fuel cut.

Just started tuning with Damond after I installed down pipe and bigger intake and re installed the ebcs in 3 port mode (had it in two port before tuning began.)
Sent me a base map to get me started with my current mods and do some pulls/logging to make sure everything was in order. He said it looked good as in nothing out of the ordinary issue wise.
Sent out a second revised base map and told me to get 2 WOT pulls on 3-4th gear to 6000rpms at least.
OverBoost happened with maf sensor code and overboost code. Damond said something is off and said to do the WOT pulls again in which he sent a new safe revised base map for me to redo the pulls on.
I cleaned the maf sensor as it was covered in a black soot and re did the WOT pulls again with the safe base map. No overboosting or mad codes this time Yay! Max boost was 20.8 psi for 2 seconds before it tapers off.
Sent the logs to Damond he replied “looks good hopefully cleaning the maf solved the issue” and resent another revised base map for what I can assume is for dialing in the power/boost.
Well I redid the WOT pulls again with the revised map and it was overboosting to 22psi+ with wgdc @ 61 % peak and it was holding that for several seconds and did not seem to actuate properly/open until the ecu did its job and initiated fuel cutting to stop from boosting even higher and a overboosting code appears of course.

I’ve done some reading.
-could be leak between hose from ebcs to turbo the boost hose portion. (I’ve routed it appropriately so I don’t think routing is an issue as problem would have been noticed earlier on)
-could be faulty waste gate actuator solenoid.
-Could be a clogged small pin hole on the k04 turbo ,apparently from what I’ve read it has that for helping with boost control or whatever I don’t know where that is exactly never took the turbo out.
- could be unmetered air from Maf to inlet of turbo which I would think would cause the opposite and be low boost. I’ve done boost leak test with smoke did not see anything out of the ordinary from turbo inlet to maf sensor.

I’m troubleshooting as of right now with these bullet points above but any suggestions from more experienced MSP3 owners that could lead to potentially resolving this issue faster would be much appreciated.
My speed has been getting more attention than my wife and two kids lately and you know what they say “happy wife is a happy life”.

 

[jsmith]

Post the logs perhaps?

 

[Easter Bunny]

Gut says tune since it went away with a different map but I would check the ecbs and wastegate to make sure both are installed and working properly. Apply compressor pressure to wg to make sure it opens

 

[philip B]

Well should have just diagnosed the problem with some compressed air before coming on here with a whole essay asking why I might be over-boosting.
I had the compressor at about 8-15 psi so I don’t think it should have been blowing soap bubbles with that amount of psi I was putting through the boost hose that comes off the turbo nipple to port three on the EBCS.

So with a leak in the boost hose to port three it was a small enough leak that a safe map could not exceed 21 psi but with a more aggressive map the leak was enough plus higher boost output with the tune to delay the waste gate from opening/actuating properly to reach actual boost targets. Let me know if I’m on the right track.

also small pin hole on the capped nipple on the waste gate. Could also have helped exacerbate the problem. Either way my zip ties that I have suck.

 

[Easter Bunny]

Glad it was easy

 

[philip B]

To add to this in case anyone else runs into this issue and to help eliminate stupid questions.

I continued to have some sporadic fuel cut and over boost code at wot even after fixing supposed leaks and boost hose leak. Would only happen with the revised map 1.03 because of the added torque and power that Damond sent out.

To Damond’s credit and explanation, turns out SWAS was the issue. As soon as I turned that crap off via in Versatuner’s software the fuel cut and over boost code were ERADICATED completely. It got so sensitive with the added power that the slightest bump/ torque steer would have me face planting the steering wheel during WOT pull logs.

 

[Easter Bunny]

If it is that sensitive you probably need an alignment

 

[philip B]

It has been awhile seems to favor the left a teeny bit. I rarely drive it( the work truck is my main) so I never paid attention to that until now.