I finally got around to installing the DDMWorks Map Sensor clip and in the process of doing so, I managed to bump my intake plenum. I was surprised to see it literally pop off the throttle body (TB). Before installing my Hahn turbo kit, I had a Hahn CAI and when I went to remove it as part of my turbo install, I noticed that my TB had some wear on it from the CAI intake plenum, so I guess the TB wore some more over time. When I initially installed the turbo system, I used a thin metal-cutting jigsaw blade in my Rockwell X2 Bladerunner to enlarge the gap in the clamping ring in hopes of getting a tighter seal, but with the wear shown, it looks like the clamp is too loose even under full clamping pressure, so I guess I may need to increase the gap in the clamp so I can get a tighter fit.
I had been wondering why my Boost gauge was typically showing boost pressures of 3 psi or less and I guess the worn fit between the TB and the intake plenum was allowing leakage and keeping my boost levels down.
I've already emailed Hahn Racecraft for advice, but I was wondering if anybody else has experienced anything similar?
I guess worst case, I need to replace the TB and probably the Intake Plenum clamp ring, O-ring and the spacer sleeve that holds the O-ring in the right spot. I also wonder if there is any sealer I could use to better seal the intake plenum/TB joint since that would be a lot easier and cheaper fix than replacing everything with new components.
Other than the lower levels of boost I've been seeing, the engine runs fine and still seems to have plenty of pep when accelerating, but now that I know I have a poor air seal at the plenum/TB, I feel the need to improve that situation.