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Since swapping bypass valves made a difference, I would probe that further. Does ESS adjust the bypass valves differently depending on the kit? Generally, you don't use more spring than you need to hold the boost you are running. The valve adjustment could be different on a 4 psi kit than on a 7 psi kit, so if you swapped valves with a 535 kit, they may not have worked on the 625 kit. ESS would know the answer.
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