[Stubok]

Hi Guys,

So I got the GSR Autosport Stage 1 Flash tune for my 328i N20 (MY14), and I almost immediately got CEL P0234 - "Turbo Charger Over boost condition". Following that I developed a boost leak, or at least that's what I think it is. I never had one with my Piggyback, so I guess the flash is pushing more boost.

I should add, I have an ATM FMIC, ER Downpipe and AFE Momentum intake. I did have the Treadstone chargepipes, but I suspected they were the source of the leak, so I'm back to the stock ones. I will be installing the ER Chargepipes when those arrive.

Anyway I got myself a boost leak tester, and plugged it onto the turbo end of the Hotside Chargepipe (leaving the other end connected to the intercooler). Only when I attached my tire compressor to the tester and fired it up, it never built any pressure, whatsoever...

So, I started trying to work out what could be happening, and while looking around the various connections it occurred to me that the pipe that attaches to underside of the cold side charge pipe just before the bend and throttle body runs across the front of the block and connects back to the intake before the turbo, so I think the air is literally just flowing back to the intake and out. I checked and there aren't any one-way valves or anything, therefore nothing to hold the air in the cold side chargepipe.

So now I'm thinking I'm going to have to connect the tester to the Intake pipe at the joint before all those other diverter and cold side return pipes connect. That way they're all under the same pressure. The turbo would also then be under that pressure, as would both sides of the diverter (so I wont be able to tell if the DV is leaking).

Has anyone successfully done a boost leak test on an N20? If so would you mind sharing your method?

As mentioned I do suspect that if the chargepipes arent the source of the leak, that the Stock Diverter valve may well be, since apparently it is very common on the N55 as well as many 2ltr VW/VAG engines. I have bought the GFB DV+ for the N20 (T9357), but upon further review, it is very difficult to install on the N20. The reviews for the DV+ are terrific from people running them. Pure Turbos is running them on the N55 and gave it a thumbs up. I'm confident it will be great for the N20 too with the added boost from the GSR tune, if only I could figure out the install. That said I definitely want to confirm that the leak is not coming from something else, before I install the DV+.

Appreciate any help guys!

[rustyminded]

very interesting. Good luck in finding that leak man, I took a log on stock map and found that car overboost most of time. hits 19 psi as normal and are that time it hit 22. it scared the shit out of me !!

[Ilovemycar]

When I took my car to the dealer a couple weeks ago to replace a failed mass airflow sensor, they performed a "smoke test" to ensure no leaks in pressure anywhere in turbo system

[Stubok]

Originally Posted by Ilovemycar

When I took my car to the dealer a couple weeks ago to replace a failed mass airflow season, they performed a "smoke test" to ensure no leaks in pressure anywhere in turbo system

Interesting! Thanks for sharing.

There are so many place that there could be a leak, and pressurizing the inlet may actually not work since it's not designed for positive pressure.

Really don't want to have to remove all my boltons so I can take it to the dealer, but may have to...

[FSociety]

Stubok how is it going ?
How come you didn't go to Eurocharged?

[Stubok]

Originally Posted by ROBNYC

Stubok how is it going ?
How come you didn't go to Eurocharged?

Not great right now. I've put the stock intake and charge pipes back and rechecked all the joints. Still have the misfire/hesitation symptom when I floor it.

I'm almost at the point where I'll put the Stock intercooler and downpipe back and take it to the dealer to diagnose.

Wish I new how to do a smoke test. Would love to be able to rule out a boost leak. Though I guess a smoke test wouldn't rule out a faulty Diverter Valve, which I suspect is at fault.

[FSociety]

Originally Posted by Stubok

Not great right now. I've put the stock intake and charge pipes back and rechecked all the joints. Still have the misfire/hesitation symptom when I floor it.

I'm almost at the point where I'll put the Stock intercooler and downpipe back and take it to the dealer to diagnose.

Wish I new how to do a smoke test. Would love to be able to rule out a boost leak. Though I guess a smoke test wouldn't rule out a faulty Diverter Valve, which I suspect is at fault.

Seems to be the same issue goon ran into ?

[Stubok]

Not totally certain it's the same as Goon's.

When I first drove with the flash, I got a cel (P0234 - Turbo/Super Charge Overboost Condition).

I spoke to GSR Autosport and they now have an updated flash that prevents this overboost issue. So I will be sending it back for an update.

My main concern now is that as a result of the overboost, I either caused a leak in the charge pipes/system or worse damaged the stock diverter valve. Apparently BMW list the replacement of the DV as a 6.5 hour job. I know because I looked at changing the stock DV with GFB's DV+ and learned this the hard way ($280 later). Basically it's impossible to replace without pulling the entire exhaust manifold/Turbo assembly.

In any case I'm going to try get a smoke test done (with bolton's), to see and rule out a boost leak. Then it will either be the DV or the tune.

I never got this before with my Piggyback. So know they didn't misbehave or leak before the tune.

The price you pay for being a pioneer... Still I'm 100% confident GSR will stand by their product and customers.

[CalCarNut]

Any updates Stubok?

[Stubok]

Originally Posted by SoCalDave

Any updates Stubok?

Unfortunately no progress yet. Have been traveling for business.

Smoke test is my project for this weekend.

[FSociety]

Stubok when you were getting the OverBoost issue did you by any chance have a obd2 dongle connected doing data logging or checking to see how much boost the car was producing?
I' want to see how much boost the car is producing then.

[Stubok]

Originally Posted by ROBNYC

Stubok when you were getting the OverBoost issue did you by any chance have a obd2 dongle connected doing data logging or checking to see how much boost the car was producing?
I' want to see how much boost the car is producing then.

Yes I did. 22PSI is what I recall being logged. I did send the file to GSR but it was so much data that it was hard to really see any patterns or issues.

[Bmw doubles]

Originally Posted by Stubok

Yes I did. 22PSI is what I recall being logged. I did send the file to GSR but it was so much data that it was hard to really see any patterns or issues.

I'm interested in the turn out too. I have a GSR tune on my N55 535i and I am starting to develop a stutter. Wondering if I've developed a leak too. No codes for me, but the DV is suspect right now.

[FSociety]

Originally Posted by Bmw doubles

I'm interested in the turn out too. I have a GSR tune on my N55 535i and I am starting to develop a stutter. Wondering if I've developed a leak too. No codes for me, but the DV is suspect right now.

As per GSR, what is the peak boost you're suppose to see in your 535?

For the N20 engine the 19.7 is pretty low(safe), I'd say max 21-22 for the N20 for long-term reliability but also depends on the mods of the car.

[Stubok]

Originally Posted by ROBNYC

As per GSR, what is the peak boost you're suppose to see in your 535?

For the N20 engine the 19.7 is pretty low(safe), I'd say max 21-22 for the N20 for long-term reliability but also depends on the mods of the car.

I have a conversation going with a few other guys and it appears there are a couple easier things to rule out first.

Clean or replace your MAF - apparently this has been a serial offender to rough running. Especially if you have run an intake that has an oiled filter. Oils carry over can coat and really cause issues with the MAF. Expect it to run a little rough when re-installed or first replaced while the ECU adjusts AFR.

Check your coils. Good chance one or two are weak.

Get a smoke test done. If you're running more boost there is a good chance you have a charge pipe leak.

On the N55 apparently it is much easier to replace the DV than on the N20... Sigh

[Bmw doubles]

Originally Posted by Stubok

I have a conversation going with a few other guys and it appears there are a couple easier things to rule out first.

Clean or replace your MAF - apparently this has been a serial offender to rough running. Especially if you have run an intake that has an oiled filter. Oils carry over can coat and really cause issues with the MAF. Expect it to run a little rough when re-installed or first replaced while the ECU adjusts AFR.

Check your coils. Good chance one or two are weak.

Get a smoke test done. If you're running more boost there is a good chance you have a charge pipe leak.

On the N55 apparently it is much easier to replace the DV than on the N20... Sigh

My issue is increasing in terms of vent to atmosphere. It purges several times now throughout 3rd gear under hard acceleration. Release and rebuild boost : /

Not so much in 4-6 gears for some reason. 2-3rd are leaky

I just order the DV+. Do you have a link that shows how to install on the N55?

Keep us posted on your findings.

Here's the I started for my leaks. We don't get much traffic over there :/

http://f10.5post.com/forums/showthread.php?t=1147538

[Stubok]

So I finally installed my DV+

It definitely behaves a better than the stock one. It really does do what they say it does.

If you install it with their piston spring, the lag goes way down and boost is held so much cleaner than before. I guess that's because there is no leakage from it like there used to be from the stock one.

I will write up a DIY and post some pics of the install. It is very fiddly, and very time consuming.

Oh and now I know my boost leak is not my DV. The stock one was fine bye the way.

Which means my smoke test is even more important now.

I reckon one of my Chargepipes (remember I'm back on stock ones while I wait for the ER ones) is leaking or one of the seals between the joints. We shall see!

[goon]

my guess is it's the tune. this is the same issue I was experiencing. you should try flashing back to stock

[Stubok]

Originally Posted by goon

my guess is it's the tune. this is the same issue I was experiencing. you should try flashing back to stock

You are probably right goon but once I have proof that there is no boost leak and the DV is also not the culprit there will be no where to hide for the tune...

[CalCarNut]

Interesting. I hope it's not tune related and just a weaklink as described.

[Bmw doubles]

Same I hope it's not the tune either. Keeps us posted.

[Stubok]

got my re-flashed ECU back today. will install tonight and hopefully get out for a drive...