Hi,

Hi seem to have poor bottom end due to building boost very slow. I do have a remap, but since the bottom end didn't change when remapped I don't believe it's related to this.

The datalogs are WOT datalogs. This it a 2nd gear run with a gear change into 3rd.

I suspected the BOV to have failed, but this checked out fine. I replaced it with a Turbosmart unit anyways.

Here's a 2nd and 3rd gear WOT run.

 

I have been thinking about checking out the wastegate, actuator and boost solenoid. Any thoughts?

 

The 1.0 ECOboost has a wastegate that functions a bit different than the wastegates of most other turbocharged engines.

On the 1.0 ECOboost the wastegate is normally open when the engine is stopped and the wastegate actuator is vacuum controlled. When the engine is running the vacuum pump on the engine puts a vacuum on the wastegate actuator which closes the wastegate valve. To prevent excessive boost pressure the wastegate valve can be opened by the PCM. The PCM uses a PWM (duty cycle) signal for a variable wastegate control.

In case of a (small) vacuum leak the wastegate will not close properly which can result in loss of power. My experience is that a small vacuum leak may not be detected by the PCM. In this case there will be no warning messages or stored DTC codes.

You should start checking the vacuum pump, vacuum lines, boost solenoid, and the wastegate actuator for any vacuum leaks. My experience is that the wastegate actuator itself is the biggest suspect. The membrane inside the wastegate actuator can rupture/split. When this happens the complete turbocharger needs to be replaced. The 1.0 ECOboost has a turbocharger that is produced by Continental/Schaeffler for Ford. This type of turbocharger is not used on any other engines. The wastegate of this Continental/Schaeffler turbocharger is not available as a spare part and until today I never found an alternative that fits this particular type of turbocharger. 

The boost solenoid is also not available as a seperate spare part from Ford. The boost solenoid is only available from Ford as part of the complete vacuum line assembly. 

Thanks for your reply.

I have a hand operated vacuum pump, so I can test the function of the actuator/wastegate (also the lines I guess).

Would you know how much vacuum the engine vacuum pump should pull? Is this vacuum monitored by the ECU?

Pumaspeed offers a OEM turbocharger replacement, though it states it can be both brand new or remanufactured. It can also be had with upgraded bearings/internals.

 

Unfortunately Ford does not specify the vacuum rating of the engine driven vacuum pump. The amount of vacuum is not controlled or monitored by the PCM. Because of this a vacuum leak is not detected by the PCM in most cases.

Alright. Since I have excellent brakes it should mean that the vacuum pump is in good shape. Does anyone have a vacuum diagram?

Made some progress today.

I vacuum tested the wastegate actuator. I pulley vacuum from the middle hose on the boost solenoid, seeing the actuator working and pulling the wastegate. It held pressure, so the actuator is good.

But, I think the problem is the wastegate linkage itself. Hard to tell without removing the downpipe and study the inside, but the linkage is pretty loose.

https://imgur.com/bLjidxT
https://imgur.com/Vk4IB9M
I'm pulling/twisting at the wastegate arm here.

When the actuator is pulley with vacuum all the way, I still have some movement left on the wastegate arm. I believe the wastegate arm would be firm if was closed all the way to the seat. The wastegate shaft bushing also seem to be worn out.

At first I was thinking about adjusting the actuator arm to give the wastegate a slightly preload when in closed position, but seeing all the slack in the wastegate shaft I'm not so sure it will work very well after all.

 

I will also need to replace my coolant tank;
https://imgur.com/oTeNRZn

There is indeed way too much movement of the wastegate mechanism. The excessive play of the wastegate shaft prevents the wastegate from closing properly which fully explains the loss of power.

To solve this problem you have basically 2 options:

1. Replacement of the Turbocharger. In this case you have to make sure to buy the correct turbocharger (depending on power output and production date Ford installed different turbochargers). 
2. Repair of the wastegate mechanism. Since spare parts are not availablefor this type of turbocharger repair of the wastegate mechanism requires machining of the turbine housing and a custom build oversized shaft. 

According to Pumaspeed the 1.0 Ecoboost turbo's are the same, even though the part numbers/power output are different.

Based on this I went on and bought a used turbo from a '14 Focus with the M2DA (100HP version) with only 6500 miles on it.

I still haven't replaced it though.

My new (used, good condition) compared to the old turbo wastegate;
https://imgur.com/9qmFqBo

It is now running better than ever.