Finally found my boost leak...any suggestions?

[rhfosu]

My APR turbo blew last February, and I replaced it with a new leftover Loba/Stasis K04 I sourced from a member here. However, it has always given me a CEL for P0299. Actual vs requested boost is 200mb low at 3500 rpm. My shop told me different reasons for this...first the turbo itself was bad (symptom was lots of oil in the inter cooler) but I replaced my valve cover and that solved that issue. Next suggestion was tightening the wastegate adjuster...but I confirmed my waste gate is cracking at 7 psi, and my tune is calling for 7psi. Well, after a smoke test, it is confirmed that there is a boost leak where the turbo muffler is pressed into the compressor housing.

Anyway, not sure where to go from here. Shop suggests a new turbo. At a minimum, this one needs to be removed to be repaired, but I am unsure how you'd repair it anyway. Any suggestions?

[EvolutionArmory]

Looks like 2 options really. Weld it closed or replace the turbo.

[rhfosu]

Talked to a turbo repair specialist...he didn't recommend welding.

Sent from my Moto Z (2) using Audizine mobile app (http://r.tapatalk.com/byo?rid=87676)

[lumberwood]

Easy decision then :(
Talked to a turbo repair specialist...he didn't recommend welding.

Sent from my Moto Z (2) using Audizine mobile app (http://r.tapatalk.com/byo?rid=87676)

- Corey

[rhfosu]

I'm in denial. This turbo is brand new practically.

Sent from my Moto Z (2) using Audizine mobile app (http://r.tapatalk.com/byo?rid=87676)

[lumberwood]

I'm in denial. This turbo is brand new practically.

Sent from my Moto Z (2) using Audizine mobile app (http://r.tapatalk.com/byo?rid=87676)How about G-Pop Shop? Rumor out there that they're worth their salt, and have some pretty happy customers. No personal experience myself, though.

- Corey

[Older_not_Wiser]

Pic of where it is leaking? There has to be a way of sealing up the leak that is not that difficult. 200mbar is like 3 psi, that has to be a pretty sizeable leak. Odd that it leaks that much around a press fit.

[rhfosu]

Pic of where it is leaking? There has to be a way of sealing up the leak that is not that difficult. 200mbar is like 3 psi, that has to be a pretty sizeable leak. Odd that it leaks that much around a press fit.It's in the seam between the muffler and the housing. You can see the oil that's sprayed out. The oil in the seam is what makes it difficult to weld. But aluminum is difficult to weld anyway. If I pull the turbo, separate the compressor housing, soak it in kerosene for 3 days, I might be able to get someone to Tig weld it.93400

Sent from my Moto Z (2) using Audizine mobile app (http://r.tapatalk.com/byo?rid=87676)

[canadianA4B7]

Have a good machine shop hack off that useless muffler and weld you just a section of aluminum directly to the lower outlet on the turbo. Aluminum isn’t hard to weld at all as long as the person is ticket (like myself) and has some experience. Likely needs to be cleaned and slightly heated up to properly weld, it should also be purge welded to ensure 100% through penetration. Plus you’ll get more turbo noise which is always a bonus. If you can’t find someone locally g pop would likely do it for you. Might not be in their listings but it’s very very easy to do. Many K04 builders are doing this to adjust where the outlet is pointing down.

[Older_not_Wiser]

Canadian seems on point with the solution for that leak, but I am not sure I would go there just yet. To lose that much boost the leak has to be fairly significant. Have you ruled out DV and/or N75 already? PCV? These are items that can cause P0299.

[canadianA4B7]

Wait just a minute. Mate just purchase new compressor housing. Swap it onto that turbo and done. Better yet remove the compressor housing ship it back to loba and ask for replacement. That’s for sure not something you’ve done to turbo they should give you replacement. It’s only 4 bolts to remove the housing.

[rhfosu]

Canadian seems on point with the solution for that leak, but I am not sure I would go there just yet. To lose that much boost the leak has to be fairly significant. Have you ruled out DV and/or N75 already? PCV? These are items that can cause P0299.

PCVs and N75 are new. I tested the PCVs also when i was running down the issue of excess oil in my intercooler lines.

I spoke with the guy who sold me the turbo today...I'm going to drive out to his shop in WV in the next few weeks and see what we can do. He gave me a handshake warranty when I bought the turbo, and he's standing by it. He's willing to remove the turbo, clean and TIG weld the press fit. This seems like my best course of action right now. As far as there being another/additional cause for the boost leak, I guess I'll cross that bridge when I get to it. But you're right...3psi seems like a lot for this press fitting to lose.