Unable to get higher than 1.6~1.7 load. Need help please!

[Camel]

Alright let me start off with "I'm a noob", I'm learning as I go and I'm happy to experiment with tuning since this is not my daily driver. That being said I've done a fair amount of troubleshooting and research and I'm unable to find a solid conclusion.

This is the mod list currently: 3" intake, CS Racepipe, muffler only, stock K04, Engine balancer delete, Autotech HPFP internals, NGK 1-step colder, Damond engine mounts and trans mount, Fidanza Lightweight flywheel, EGR delete, stock TMIC, stock EBCS, 150-152psi across all cylinders, 91 pump gas

What I've done hardware specific:
Found and fixed boost leak, VTCS solenoid bottom nipple was leaking.
Pressurized smoke test up to 20psi and no smoke was seen after fixing leak.
Found and fixed an exhaust leak between manifold to turbo flange, 2 of the 4 turbo flange bolts were basically dancing around.
found and fixed exhaust leak between turbo to downpipe flange, missing a nut and had a loose stud on the flange, torqued all loose bolts to spec. (exhaust leaks were also evident due to black soot on the heat shielding)
Verified EBCS solenoid activates and de actives when given 9 volts directly. (I can hear a little click and I was able to blow air through it when voltage was applied.)
Verified EBCS solenoid hose routing is correct, hose closest to EBCS harness connection goes to turbo wastegate actuator, hose closest to firewall goes to turbo inlet pipe.
Verified the waste gate actuator opened and closed smoothly when metered air pressure was attached.
I even pinched off the waste gate actuator from the EBCS and it made no difference in boost or load.
feels like WGDC isn't doing anything at all. I could try swapping EBCS solenoids from my other speed3, but I dont think the EBCS is the issue if giving it voltage directly makes a click and allows air to pass through.

What I've done software specific:
MAF is calibrated Okay +-5% LTFT
zeroed BCS DC Base table (no difference - 11-13 psi boost 1.6-1.7 load)
copy and pasted stock tune BCS DC Base table values (no difference - 11-13 psi boost 1.6-1.7 load)
copy and pasted VersaTuner 91 Octane BCS DC Base table values (no difference - 11-13 psi boost 1.6-1.7 load)
copy and pasted VersaTuner 93 Octane BCS DC Base table values (no difference - 11-13 psi boost 1.6-1.7 load)
increased APP Requested Load Normal / Overload values
increased Requested Load for 3rd and 4th gear Limit Low BAT values

Attached are both my latest tune file and a WOT log for that specific version tune file. Also (2) 3rd Gear WOT logs before and after the leaks were fixed on an earlier revision of the tune file.



I'm down to these conclusions:
I have a leak somewhere still (Could my turbo wastegate flapper be cracked open and slightly leaking enough to limit boost?)
I do not know how to use VersaTuner AT ALL and I'm just missing something very small but crucial. (very likely)

I'm desperate for help lol, I've googled, I've chatgpt'd it, browsed versatune forums, mazdaspeeds forums, I've tried using common sense, and even after fixing what I thought was the issue ended up being not making a difference at all.

Any help is appreciated, I hope everyone had a merry christmas and a happy new year when that rolls around!

 

[Enki]

Couple things to note:
1. The car is running INCREDIBLY rich. This is a bit dangerous, as it's likely to wash down your cylinder walls.
2. Boost is following the efficiency curve of the engine at spring pressure, so you're right that the EBCS isn't doing anything, or at least appears to not be doing anything.

Recommendations are to take some pics of how you have the EBCS hooked up to the turbo, and to remove all hoses going to WGA (except the one that goes from WGA to turbo, as we know for sure that one works) and make sure all those hoses and the EBCS can flow air when energized...Might be plugged up.

Factory K04 uses a bleed style setup, if memory serves, so if there's a clog (or the EBCS isn't working properly) between WGA and intake (not mani, just turbo intake), then you'll only ever get spring pressure.

 

[Camel]

Couple things to note:
1. The car is running INCREDIBLY rich. This is a bit dangerous, as it's likely to wash down your cylinder walls.
2. Boost is following the efficiency curve of the engine at spring pressure, so you're right that the EBCS isn't doing anything, or at least appears to not be doing anything.

Recommendations are to take some pics of how you have the EBCS hooked up to the turbo, and to remove all hoses going to WGA (except the one that goes from WGA to turbo, as we know for sure that one works) and make sure all those hoses and the EBCS can flow air when energized...Might be plugged up.

Factory K04 uses a bleed style setup, if memory serves, so if there's a clog (or the EBCS isn't working properly) between WGA and intake (not mani, just turbo intake), then you'll only ever get spring pressure.

Alright, so I have 2 speed3s and I had another stock K04 laying around. I swapped the WGA from the spare K04, to the current K04 on the black speed3 as a last resort and after a few hours and slamming my fist into the firewall, I was able to get it all installed and did a quick run. I was able to push 17psi all of a sudden, felt great getting more than 13 for once! The original WGA I removed from the original K04 does have a spot that if I pull on seems to kind of bind in a specific spot. I'm very happy now and I can continue figuring out the tuning part lol. Thank you @Enki for your help and your suggestions!

Solved!

 

[Enki]

Probably stuck open then. Make sure you reset the ECU so the WG control doesn't cause a window in the block.

 

[Crazycanadian]

Alright, so I have 2 speed3s and I had another stock K04 laying around. I swapped the WGA from the spare K04, to the current K04 on the black speed3 as a last resort and after a few hours and slamming my fist into the firewall, I was able to get it all installed and did a quick run. I was able to push 17psi all of a sudden, felt great getting more than 13 for once! The original WGA I removed from the original K04 does have a spot that if I pull on seems to kind of bind in a specific spot. I'm very happy now and I can continue figuring out the tuning part lol. Thank you @Enki for your help and your suggestions!

Solved!

Looks like you are using one of the Versatuner base maps as your starting point.. Looking at your tune, you haven't done much yet.. Even though your AFR's look good, your MAF calibration is choppy. I've seen worse and this might not cause issues, but it's not correct either.. It needs to be smoothed out. The final hump around the 3.9V range needs to be smoothed into the higher voltage range to get rid of the hump.



Your APP Mapping for 1st and 2nd gear is weird.. You've got some funky things going on between how you've set it up and how the multiplier speed adjustment works with it..



When you were testing with the APP Load Request tables you killed your throttle resolution/modulation ability making it more of an on off switch..

When it comes to tuning, forget about "boost/gauge" pressure and log the raw MAP reading... All of the boost pressure safties and limiting tables are based on Absolute Pressure.. Load calculations translate into Absolute Pressure. Nothing to do with tuning care's about what "boost/gauge" pressure you are making.. This becomes important if you are hitting limits and/or trying to diagnose or get advice around the limit tables.

What are you using to look at your logs?

 

[Camel]

Looks like you are using one of the Versatuner base maps as your starting point.. Looking at your tune, you haven't done much yet.. Even though your AFR's look good, your MAF calibration is choppy. I've seen worse and this might not cause issues, but it's not correct either.. It needs to be smoothed out. The final hump around the 3.9V range needs to be smoothed into the higher voltage range to get rid of the hump.

View attachment 33873

Your APP Mapping for 1st and 2nd gear is weird.. You've got some funky things going on between how you've set it up and how the multiplier speed adjustment works with it..

View attachment 33874

When you were testing with the APP Load Request tables you killed your throttle resolution/modulation ability making it more of an on off switch..

When it comes to tuning, forget about "boost/gauge" pressure and log the raw MAP reading... All of the boost pressure safties and limiting tables are based on Absolute Pressure.. Load calculations translate into Absolute Pressure. Nothing to do with tuning care's about what "boost/gauge" pressure you are making.. This becomes important if you are hitting limits and/or trying to diagnose or get advice around the limit tables.

What are you using to look at your logs?

So the MAF calibration is crap lol, I just hadn't taken the time to smoothen it out since I was having issues with commanding higher load. I also found the MafCals post by JohnyTightlips that helped a ton and is 95% perfect now (and way smoother of a curve lol)

APP mapping for 1st and 2nd gear was me experimenting with launches on dirt. The idea is to give me more granular control up until around 30-50% in 1st gear. Unless I'm not understanding how the APP mapping works... I'm turning the speed3 into a rallycross car. I know the speed3 platform is not meant for anything remotely offroad, however I like to try weird things.

And about the mulitplier speed adjustment, in the table information it mentions that raising the value can aid in starting from a stop more easily for vehicles with lightweight flywheels.

The APP Load Request tables did kill my throttle resolution, i was experimenting and seeing if the reported APP max when logging (67%) was limiting me from achieving higher loads.

I know the in dash boost guage isn't accurate at all, but its an easy way to glance down and see if the previous changes made any significant differences since i was always stuck between the "7+ and 15+" marks on the in dash boost gauge. I'll start using the MAP readings now.

I've been using a the versatuner built in log viewer as well as tunezilla.com to get some side by sides. I havent searched for any better alternatives.

 

[Enki]

I know the speed3 platform is not meant for anything remotely offroad, however I like to try weird things.

 

[Raider]

Only weirdos lift their speeds.

 

[Crazycanadian]

So the MAF calibration is crap lol, I just hadn't taken the time to smoothen it out since I was having issues with commanding higher load. I also found the MafCals post by JohnyTightlips that helped a ton and is 95% perfect now (and way smoother of a curve lol)

APP mapping for 1st and 2nd gear was me experimenting with launches on dirt. The idea is to give me more granular control up until around 30-50% in 1st gear. Unless I'm not understanding how the APP mapping works... I'm turning the speed3 into a rallycross car. I know the speed3 platform is not meant for anything remotely offroad, however I like to try weird things.

And about the mulitplier speed adjustment, in the table information it mentions that raising the value can aid in starting from a stop more easily for vehicles with lightweight flywheels.

The APP Load Request tables did kill my throttle resolution, i was experimenting and seeing if the reported APP max when logging (67%) was limiting me from achieving higher loads.

I know the in dash boost guage isn't accurate at all, but its an easy way to glance down and see if the previous changes made any significant differences since i was always stuck between the "7+ and 15+" marks on the in dash boost gauge. I'll start using the MAP readings now.

I've been using a the versatuner built in log viewer as well as tunezilla.com to get some side by sides. I havent searched for any better alternatives.

I've got a spread sheet I use for building MAF cals from logs..

When it comes to data logging get your self Megalogviewer HD.. You can get the Non HD version for free, but trust me. Pay for the full version, it's super cheap.

If you want I've been working on a series talking about tuning in the build thread for my Speed6.. You're Gen2 has some differences with open/closed loop fuelling and spark maps..

I just made a post talking about how the APP request load tables work with the Closed Loop to Open Loop APP threshold tables, and Closed Loop to Open Loop APP Load Threshold tables.. The Requested Load - 1st, 2nd, 3rd ect.. It's important to understand how these tables switch, when they switch and what they are doing when they are switching.. The APP Mapping tables control how far you move the peddle in order to access different area's of these tables.. These tables all work the same between Gen1 and Gen2 stuff..

You are right, the APP speed tables are used for taking off/parking lot driving, but it uses the APP Mapping tables as the starting point and builds on it.. So if you are doing funky things with the Mapping tables, you'll have to compensate for it in the Speed tables and understand how to blend both of them together in order to avoid weird things happening at different throttle and low speeds..

All of these tables working together give you that granular feeling you are after..

Launch control and flat foot shifting is done in different area's of versatuner that isn't part of the tables.