not making boost

[davidgtr]

I put a gt3582 turbo on my car and now i'm making less boost then before.

The old turbo (k04) was making 17psi but now the most i can make is 7psi
This is where it gets weird, I installed everything and then test drove it and could only make 7psi.
Then I done a boost leak test and found 3 big leaks and I sealed them.
After I fixed the boost leaks I test drove the car again and could only make 5psi, exactly that don't make any sense,
So after that I started looking at the wastegate and the easiest was to test was to remove the wastegate and make a flange to block the hole.
So i went for another test drive and was expecting the boost to go out of control but the most I made was 5psi again.
I also checked to turbo shaft and it is ok.
At this point I am lost and not really sure what to make of this.
Does anyone have any ideas where to look next because at this point i'm sick of this car, it has been nothing but a problem child from the day I got it.

[Crasher]

So this is a Golf 4 with an AGU engine?

[davidgtr]

Sorry I forgot about the car.
Audi a4 b6 1.8t quattro avj/awt

[Crasher]

Do you have diagnostic equipment equipment such as full VCDS?

[davidgtr]

Do you have diagnostic equipment equipment such as full VCDS?

Yes I do. I just went out and scanned the car and this is what i got.
p0106 map sensor implausible signal
p1548 n75 open circuit
p0420 cat system bank 1 efficiency below threshold

I can explain all these. The map sensor fault is because i'm running the diode mod and was running this for 6 months before i changed the turbo.
The n75 is because i dont have an n75 connected, I use a ebc. The cat system is because I have no cat.

[Crasher]

The MAP and N75 are key, I can't look it up at home beacause my work PC died and my home PC is, at work.... I would say the N75 isn't being driven, on your car a good bet would be water damage in the ECU box.

[davidgtr]

The MAP and N75 are key, I can't look it up at home beacause my work PC died and my home PC is, at work.... I would say the N75 isn't being driven, on your car a good bet would be water damage in the ECU box.

I'm positive that the n75 and map have nothing to do with my problem.
I removed the n75 about a year ago and replaced it with the electronic boost controller and it worked perfect on the k04 turbo.
I can test the map sensor and see what happens but I don't think that is the problem.
The problem is that since i put the gt35 turbo in it wont spool and wont make any usefull boost.

[Crasher]

So what are you using to control the wastegate?

[davidgtr]

So what are you using to control the wastegate?

I'm using an electronic boost controller which worked perfectly with the k04 turbo.
I also removed the wastegate to try to make the boost go out of control but I still only made 5psi si I know that the wastegate is not the problem.

[Crasher]

If the wastegate is shut, the turbo working and the charge air system tight then you have a fundamental problem such as poor combustion, blocked intake or a blocked cat, drop the downpipe off the blower and try it...

[Crasher]

I don't know why this closed????

[davidgtr]

Ok so i figured out what was wrong and it was a massive exhaust leak between the manifold and the head.
34404
The reason it was leaking is incredibly stupid.
34405
Somehow I had one of the washers behind the gasket and them washers are 5mm thick. I don't know how the hell it got there but atleast it was an easy fix.

[Crasher]

We all do things like that, Doh! moments......