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leusgs

Member Since 16 Jan 2015
Offline Last Active Aug 26 2015 03:29 AM
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My Code 66 Journey - 1999 JDM Legacy GTB E-tune EJ206 twin turbo

16 January 2015 - 03:19 PM

I am in the middle of diagnosing code 66 troubles on my 1999 Legacy E-tune JDM wagon.

 

Here's the background:

 

The car has 72,000 kms and is in very nice original condition.  Appears to be very well looked after.  It runs smooth, starts and idles well, gets decent fuel economy, and is generally a car I'm quite happy with.   BUT - There is no secondary boost.  Never has been since I got the car 3 months ago.  It has great power at partial throttle from about 0-3000 rpm but then falls flat.  I assume the primary turbo is working at this low rpm range.

 

Above ~4000 rpm, the car falls flat.   It feels like the wastegate is opening or something, and it has little power over 4000 rpm.  It feels like a non-turbo car.  Here's a video of the dash - you can see it pulls ok until 4000 then is just stops!

 

 

Check for codes reveals code 66.  The first thing I did was find a used BBOD from a friend's B4 RSK that is a good running car.   Swapped the BBOD and unfortunately there was no change.   Then we tried his MAF.  No change.   Then we tried his primary/wastegate solenoid.  No change.   Then his Differential Pressure sensor.  No change.

 

I've put a hand vacuum pump on the Wastegate and added + pressure and it moves like it should.   Same for the Exhaust valve for the second turbo, and the air intake valve under the intercooler.  Everything moving freely when manually pumped.

 

I next connected the green wires under the dash and can feel and hear all the solenoids clicking.  The Exhaust valve moves in and out until the vacuum tank empties after a few seconds.  Same for the air intake valve under the intercooler.   I also checked the valve operation while revving the car manually up to about 4000 rpm - and both valves open when the rpm gets high.  So all appears normal there.  I think?

 

I've checked all Vac hoses and all are original with the original pills.  I've put vacuum and all the hoses and none are leaking.  They are in very good shape with no cracks and all very flexible. 

 

I connected the green connectors and went for a drive.   I got code 32 while driving the car.  (Oxygen sensor).   I've never had code 32 while checking the static codes with the black wires connected.

 

I'm at a loss here.  Have I missed anything?   My only ideas are as follows.  Do they have any merit?

 

1) clogged catalytic converter?

2) something under the intercooler not right (cracked intake piping?)

3) O2 sensor is causing the code 66 and no-boost issue.  Not sure if this even happens?

4) Knock sensor is bad causing knock signal and telling the computer to open the wastegate?

 

As you can see I am guessing!   Your ideas are appreciated.   I'm going to pull the intercooler and look around for something obvious under there next! 

 

thanks.