What Happens If Your Solenoid Is Stuffed?

[wrxkilla]

I spose this is a continuation of previous threads...

http://www.fordxr6turbo.com/forum/index.ph...topic=30497&hl=

then moved into this one after everyone bashed the tuner and made some guesses...

http://www.fordxr6turbo.com/forum/index.ph...topic=30852&hl=

Basically, since then... Ford replaced 'some' clamps (Bu they was still crap), Ive been through and checked EVERY vacuum hose, taken off inspected, reseated, every intercooler pipe etc, replaced Every Clamp myself with decent ones.

Checked reseated the crossover pipe a million times.

Did find a missing bolt from the turbo-manifold now replaced. Double checked since manifold and turbo bolts.

Cleaned the solenoid out with wd-40.

But all this doesnt seem to have fixed the problem.

I have attached an image last time it was on the dyno with this problem. You can feel this surging of the boost fluctuating in the car. before it picks up and goes...

So is this a faulty solenoid or an actuator problem... (Starting to boil down to the only 2 things left?)

getting sick of it now, gonna sell this pos if I dont find it soon. lol

Im not the kind of person that replaces parts willy nilly. I like to know why its broken see the proof and replace only that part.

Otherwise you end up replacing 10 things at a cost of 3 grand or so before you fix the problem. lol

cheers for any help. I appreciate it.

Michael

[ROLMDL]

Mate as you know I have the simaliar problem to you with the surging problems but its a on and off thing some tiems it wont sometimes it will.

but I personaly think it lacking power in the mid range im gonig to see nick on monday to try fix the problem and mabye change few things on the map.

[wrxkilla]

yeh defo getting it on the dyno is a good idea.

as I now have a dyno graph of before problems and now problems, its giving me some clues at least.

the boost going up and down in that above attachment explains the feeling I get.

just need to know if anyone has had it before!!!

:D

[Blonk]

Check hoses and cooler for cracks......

A new boost solenoid will cost you about 12 bucks and takes about an hour to replace... Rule that out first before you head to the actuator and wastegate... Big Job........

To check the wastegate is not leaking, remove the vacuum line to the actuator, then go for a drive. Boot it and see if it stil fluctuates. BE CAREFUL AS THE BOOST IS NOW NOT CONTROLLED AND CAN BOOST TO 20 + PSI IF PUSHED HARD.. Just accelerate and feel the boost spooling and see if it is consistant.. Once again... BE WARNED YOU CAN OVERBOOST and blow the sucker to peices... TAke it easy and you will see what I am talking about....

If your car has had a chip in it that has been removed for edit then you may have some faulty wiring.. IE boost controller to solenoid... Went through 3 months of this in my XR.......

Edited 07/01/07 04:25 AM by Blonk

[wrxkilla]

thanks blonk

I thought for some reason the solenoid was more expensive?

if anyone has a part number I'll order one and pick up tomorow???

as stated above, spent full day removing every intercooler hose and every vacuum hose, double checked tham all. and re-fitted some new clamps to everything! :D

I'll defo buy a new solenoid, I expected they be $100+ from ford lol.

cheers

Michael

[Blonk]

Suprisingly most dealers carry them in stock, I think I picked up mine at the Ford spare parts near chermside.....

I will see if I can find a part number.......

[wrxkilla]

Denmac Indroopilly (Brisbane) dont have any instock. $39

will arrive tomorow...

will let you know if they have the right thing (ie price is off what you said) tomorow.

:D

Edited 08/01/07 04:53 AM by wrxkilla

[wrxkilla]

Picked up the solenoid today from Ford.

Will pop it in tonight when I get home....

Hopefully this is the fix.

does anyone forsee the problem being the actuator? spring having problems controlling the flap?

ah well see tonight, as I spose actuator is next?

cheers

Michael

[Blonk]

Must have gone up a lot.. I could have sent you a new one from up north here for a few bucks postage (if I can find it).... If it doesnt fix it, just take it back,,, If it does fix it then it is cheap.....

[4ST-XR6]

Ive seen a car do something similar, the car came on boost fine and hard, then at approx 3600rpm the car started to surge and almost have a misfire, it was overboosting heavily, I was suspecting the wastegate control solenoid of perhaps pin hole or tear in the actuator diaphragm. The car hasn't been back since, and I was only allowed to spend half an hour on the car as it was customer charge, not warranty and the customer didn't want to spend heaps of coin, Is your car playing up about the same rpm and the one I had? I couldn't download the dyno sheet for some reason. If I come up with anything I will let you know, but the previous posts are on the right track.

cheers and goodluck