If that's 30psi on ECM it's actually 14.7 over.
I still think you have a boost leak, did you every check intake torques? And I forget what the egr was doing.
Pressure test the boost system with the engine off, should be able to hear where it's leaking if it is.
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I really don't think he has a boost leak, since the gauge would be under reporting ,not over reporting/reading(Depending on where the sensor is placed). Plus it sounds like the mechanic has double checked the plumbing and I would think he would have heard it by now.
This isn't about doing it right the first time. The vnt-17 is a great, economical, reliable choice, not everyone has the desire to run block girdles and run ridiculous sized injectors for 30+ psi of boost and everything else that goes along with it.
This guy is diagnosing a funky issue and is having a lot of bad luck at the same time. Telling him to spend $1600 on a turbo that will mask his problem is bad advice.
I agree the VNT-17 is very good turbo for an affordable price, but it sounds like Judson is pushing his VNT-17 to it's limit and with his issues a little bit beyond what it is capable of. That's why I recommended he upgrade to a more appropriate turbo that will be able to handle the boost he's looking to make. I don't see how that is bad advice?
He can upgrade the turbo and still continue you to diagnose what is causing his boost spikes, since they will still be happening no matter which turbo he's running, except the GTD1752VRK won't grenade at 30 psi saving him the hassle of buying another new VNT-17 at $800 plus the labor of installing it, cleaning out the intercooler and piping adds up pretty quick. And he's had to do that for 3 turbos, so the $1600 GTD1752VRK is looking a lot cheaper than say $2,300 in turbos plus labor of say $1,200. Call it $2,000 for the GTD1752VRK and install or $3,500 in turbos and labor, I know which route I would have gone.
pp520+ 11mm pump will max around 165-170whp on this turbo with aggressive fueling and is definitely pushing your luck reliability wise. Heck you can break just about anything if you try hard enough, when you're getting into these kinds of mods it's best to drive appropriately; downshift when doing highway pulls, run gauges, don't launch in 1st etc. boost and egt gauges are a lot cheaper than turbos.
What is in bold and larger font is exactly why I'm recommending the next size up turbo and you get the benefits of the latest in turbo technology.
I understand that some people are looking for an affordable turbo to replace their worn out or broken stock turbo and want a little bit more robust turbo, but if you're spending money on a larger injection pump, FMIC, good sized nozzles, and other supporting mods I don't understand why you wouldn't wanna get the most modern turbo available to you at that time.
For me when I had my turbo go back in 2008, the most reliable turbo that provided a decent gain in power at the time was a VNT-17/22. Even though it is capable of 28 psi, I wasn't quite there for that much boost, since I had the factory MAP sensor, SMIC, injectors, exhaust, etc, so I had Jeff at Rocketchip tune for my hardware. As I could afford it I upgraded little by little and with each upgrade sent my ECU to Jeff to tweak the tune for whatever piece of hardware was upgraded. Now you guys get it easy with Flashzillas and emailing tunes back and forth.
End of rant