Chasing phantom zeroed out wastegates and no cel

[EcoInterceptor]

Hello everyone I am a new member to this forum and this is my first post. I did utilize searching just about everywhere I could fathom before bringing up this delema I'm facing. This is my 3rd ecoboost and 2nd interceptor sedan. This one has myself, 2 dealerships and another shop stumped. 1 dealership sort of may have caused it but not sure yet. I had it brought to another dealer to go over it and it's a touchy subject. They don't want to get involved with the repair they did without completely replacing parts that I would have to come out of pocket for and then try to have the other shop pay it back. And with that they were not sure that even that is or would fix the issue. So.. Here it is

I have a typical po299 low boost code with no cel and did data log both with forscan and an sct4. My car does have a tune but the issue was present before and it was another means to data log and test with the hope of it getting resolved to enjoy the tune after.

Forscan always shows it happening around 4th gear and 4-5k rpms. Sct shows any time after the typical 5 seconds of desired boost not met. I have tested for boost leaks via smoke and compressed air and even pulled out the entire intake system to test individually. I found 1 split factory clamp on the inlet side of the front turbo and I simply replaced it with a hose clamp.
I have tested both bov and bought 1to keep around for future testing and mine were fine. I have tested and purchased a ebc to keep around for future testing and again it was fine.
I have both a 2br and a 2.5 bar map sensor. 2bar for factory tune and 2.5 for gearhead tune both work fine. Plugs have maybe 5k on them, coil packs are good, timing chain/timing is good, tps I tested and the old one did have a dead spot so I replaced it with a throttle relearn after, no coking or blow by in plenum(slightly had but cleaned when intake was removed), no leaks at manifold gasket or misc vacuum lines, no misfires or any other issues what so ever In fact I'm getting 18+mpg at the moment lol. Wastegates function as they should and hold vacuum as well. Turbos spin freely and no shaft play. I'm sure I'm forgetting something but I'll move along..
The fun part... The dealer I took it to for an exhaust Leak confirmed that it was the y/flex pipe and what it cost for the part. They said it could be welded and much cheaper and faster as the parts were back ordered. I of course agreed to it and ibpicked up later that day. It was fixed and at first seemed fine but I didn't really get into it right away. The next day I did and it took off as normal but around 4k I felt a loss of power and not the same. No cel on the dash so I got to my destination and it definitely felt off. Turned it off and went in store, came out left and it was back. So went at it again and about the same time it did it again. Went home pulled out forscan and confirmed it. Now then it was sti making some boost but now it get to 5lbs and then zeros out the wastegates. Cats are at 1200 max and like I said before everything including the turbos and wastegates function fine.
On 1 of my data logged journeys I noticed that the accelerator pedal position was at 14.90%at idle and jumped around and the throttle body percentage hovered between 2.5and 4.8. Not sure if this is normal so hence the question.

Everywhere I go wants to charge 3-5k to throw parts at it and I just don't have that kind of money for that. I apologize for the long post but wanted to try and give as much info as possible. Any help is greatly appreciated and needed lol

 

[SHOdded]

p0299 usually means the wastegate actuators are dead. could be simple cclips on the actuators not being in place tightly enough, or could be physical detachment of the actuator from the turbo. doesnt sound like wastegate control issues but worth checking the hoses attached to it anyway since they are unclamped. would set separate codes tho, could be threshold is not reached, but ...

i would check those cclips first.
next examine the turbo piping specifically under the plastic clamps - known to leak from there

it is possible you are just at the beginning of the issue, so you are not seeing the real culprit just yet.

 

[EcoInterceptor]

Thanks for the info man. Yeah I tore the entire system apart except for actually pulling the turbos themselves. Actuators are attached and move through entire cycle with no binding or sticking. I removed the plastic clamps and replaced them with tbar clamps to be sure that was not the issue. I'm leaning twords the accelerator pedal position sensor and or possibly the harness issue given that the rest of the system checks out.

 

[SM105K]

It could be the charge piping itself or the coupler on the rear turbo. Both are are known to crack. However if you leak test it, they will hold. It isnt until you get under boost that the crack opens and vents boost to the atmosphere. Also is the seal for your MAP sensor leaking? You said you tested the BOV's. Did you check the silicone gaskets?

 

[EcoInterceptor]

Thanks for the reply sm105k. I used a smoke machine first with everything still connected in the car, then I used a compressor with a homemade adapter and pressure gauge but also put some air to the wastegate lines to check if they would actually hold air, then since the stupid intercooler is known to leak I removed all the intake plenum, hit the intercooler by its self, bench tested all of the tube's individually with smoke and air again, reinstalled and hit it with air again. About 20psi. I did voltage and pressure tested the bov, ebc, maps, intake manifold it's self as well. Ohmed out the tps, iat, and cts. I used a vacuum pump on the wastegates and made sure they were not sticking, no shaft play, no coming or oil jn intake plenum, no missfires, plugs and coils were done maybe 5k ago, timing chain was done 10k ago, phasers as well, no trans issues, cat temps never get above 1300, o2 system is good, trims are good, injectors and fuel system is good and just about everything else is gravy. No cell, not a single driveabilaty issue what so ever.. I fact my mpg has gone up lol. No smoke, no damage to impeller or anything. Just gets to about 4-7psi for more than 5 seconds and wastegates go flat. I even wired the gates shut on the downpipe to see if I would even get a blip of boost and nothing different happened. This is beyond bananas my friend haha

 

[SM105K]

Have you check the boost control solenoid?

 

[EcoInterceptor]

Yes sir and replaced it as well.. Sorry Iwas calling it the ebc(electronic host control)

 

[SM105K]

I PM'd you.

 

[SHOdded]

the diaphragm on the blowoff valve is known to tear. just something to check.

if its not physical, it is electronic. up to and including the pcm.

 

[EcoInterceptor]

Sm105k I got your pm and I shall shoot that to you when I get to my pc. They changed shifts on us and kicked it up to 7 days 12hrs until end of June lol. I'll send you both the forscan and the sct logs.

 

[SM105K]

Sm105k I got your pm and I shall shoot that to you when I get to my pc. They changed shifts on us and kicked it up to 7 days 12hrs until end of June lol. I'll send you both the forscan and the sct logs.

No worries. No rush.

 

[EcoInterceptor]

So been busy moving, working overtime(7-12's and moving to a swing shift schedule) and poking at the car whenever I get a moment. Even if it is on my lunch break lol. Sm105k I did not for get about sending you the logs and actually will have tomorrow off to do so lol. I have found the issue and honestly I dont know how to even approach the reason or how idiotic it is for any reason even if it was accidental. I'm trying to keep my mind on accidental or anything other than deliberately being an a**hat. So I had tested everything you could fathom with the exception of 2 things. Given the information given from the car it's self and not having access to certain tools I was left with either a bad harness and/or pcm issue or an issue with the exhaust, cats, flex pipe or wastegate door. So I chose to do the exhaust first as the last actual issue the car had was a leaking flex pipe that the actual dealership repaired by welding. So I jacked the car up and crawled under it and found 1 pipe from the rear turbo before the flex pipe actually out of round from being hit from the top of it by a hammer. Not fully shut but definitely dented from the blows and out of round about a 1/4". So after expressing my thoughts verbally for a few moments I moved down to see about removing it to repair. I get to the ****** from the flex pipes to the 3rd cat and I see orange rtv on the ****** where the gaskets would go. I then knew where the issue had to be but I would've never thought anything like this. I found about half a roll of regular Reynolds wrap aluminum foil stuffed through the flex pipes, into the down pipes, into the 3rd cat, past the 3rd cat and literally packed into the actual internals of the 3rd cat. Now I say packed Into the cat because it was lined on both sides and not just ruffled like it was blown inside. So I left it unhooked at the ****** and pointed the flex pipes facing down and out. I removed what I could from the forward exhaust and said **** with it. I started it up and creeped out of the drive and out in the road. I rolled into it and punched it! It blew the rest out the back and took the **** off! The 3rd cat is toast no matter what so it's time for a cutout upgrade and delete. I know of some situations to pack material for welding but the dumb crap I found leading up to this makes me believe this was deliberately done and I'm still trying to figure out what I'm going to do about it.

 

[SM105K]

That is interesting. The good thing is, you can 100% delete the third cat without any CELs. Just leave the resonator or upgrade it because if your don't, the car will drone.

 

[SHOdded]

So been busy moving, working overtime(7-12's and moving to a swing shift schedule) and poking at the car whenever I get a moment. Even if it is on my lunch break lol. Sm105k I did not for get about sending you the logs and actually will have tomorrow off to do so lol. I have found the issue and honestly I dont know how to even approach the reason or how idiotic it is for any reason even if it was accidental. I'm trying to keep my mind on accidental or anything other than deliberately being an a**hat. So I had tested everything you could fathom with the exception of 2 things. Given the information given from the car it's self and not having access to certain tools I was left with either a bad harness and/or pcm issue or an issue with the exhaust, cats, flex pipe or wastegate door. So I chose to do the exhaust first as the last actual issue the car had was a leaking flex pipe that the actual dealership repaired by welding. So I jacked the car up and crawled under it and found 1 pipe from the rear turbo before the flex pipe actually out of round from being hit from the top of it by a hammer. Not fully shut but definitely dented from the blows and out of round about a 1/4". So after expressing my thoughts verbally for a few moments I moved down to see about removing it to repair. I get to the ****** from the flex pipes to the 3rd cat and I see orange rtv on the ****** where the gaskets would go. I then knew where the issue had to be but I would've never thought anything like this. I found about half a roll of regular Reynolds wrap aluminum foil stuffed through the flex pipes, into the down pipes, into the 3rd cat, past the 3rd cat and literally packed into the actual internals of the 3rd cat. Now I say packed Into the cat because it was lined on both sides and not just ruffled like it was blown inside. So I left it unhooked at the ****** and pointed the flex pipes facing down and out. I removed what I could from the forward exhaust and said **** with it. I started it up and creeped out of the drive and out in the road. I rolled into it and punched it! It blew the rest out the back and took the **** off! The 3rd cat is toast no matter what so it's time for a cutout upgrade and delete. I know of some situations to pack material for welding but the dumb crap I found leading up to this makes me believe this was deliberately done and I'm still trying to figure out what I'm going to do about it.

WT sctual F!!! good on you for your persistence, hope this finally resolves it.