Limited boost with my new turbo...check my logic

[reklund]

So as you may know, I recently installed a new Aurora 2000 Turbo kit from ATS on my truck. I initially installed it with my intercooler NOT hooked up, as it required modification to the intake hat and piping.

On the initial road test, the truck ran well, but only boosted to like 4 psi. I attributed this to the wastegate being set incorrectly, and adjusted it to get between 6 and 7 psi at WOT. I ran the truck like that for a week or two while I gathered parts to re-connect my intercooler.

This weekend I got my intercooler hooked back up, and immediately lost 2 psi. That sounded about right considering I added 8 feet of plumbing and an intercooler core to the intake tract, so i adjusted the wastegate again to get back to my 6-7 psi. I made a few runs and saw that my EGT's were nice and low so I figured I could push the boost up a bit. I maxed the wastegate adjustment at this point, and cant get past 7 psi.

I thought I might have a boost leak, so I disconneted the boost line to the wastegate and made a run- again without passing 7 psi.

I figure I've got a leak in the intercooler plumbing somewhere- either at the intake hat I made, or in the silicone couplers. I'm thinking I can hook a smoke machine to the intake plumbing if I make a couple of caps out of PVC or the like and check it out. I think it'll be hard to check the intake hat the same way, since I'll likely have intake valves open somewhere and won't be able to build enough pressure to get smoke out of the hat-to-manifold sealing area.

Anybody got any good ideas? For the money I spent on this new wastegated turbo, I sure thought I'd see some more boost. I don't know if it's just the mile-high altitude here causing me to see low boost or if I just don't have the timing or fuel set correctly.

I still have the DPS injection pump in there (and leaking a bit on my valley pan ) and judging by the smoke I figure I've got plenty of fuel. I set the timing myself with my MT-1480 and as I recall, its DEAD ON.

Ryan

 

[FordGuy100]

Yeah, it sounds to me like you have a boost leak somewhere. Have you tried some water/soap/water dye on them? Might bubble up and the coloring would make it easier to see .

But if you disconnected the wastegate and your only seeing 7psi, I'm willing to bet you have a leak somewhere.

 

[DeepRoots]

don't forget exhaust leaks too, tho they tend to be noisier and easier to spot.
I dunno about a smoke machine, but soap and water has never failed me.

 

[reklund]

I've got this ******* new Snap-On smoke machine at work that is designed to test for leaks in an EVAP system on a new car. I figured it'd be perfect for this, but soapy water would work great too. And probably be easier...

I'll Check into it tomorrow. All my connections look and feel good, but maybe the fender skirt has rubbed a hole in a IC pipe or something...

Ryan

 

[schoelta]

I've got this ******* new Snap-On smoke machine at work that is designed to test for leaks in an EVAP system on a new car. I figured it'd be perfect for this, but soapy water would work great too. And probably be easier...

I'll Check into it tomorrow. All my connections look and feel good, but maybe the fender skirt has rubbed a hole in a IC pipe or something...

Ryan

An EVAP smoke machine will not work, and it won't produce enough pressure. EVAP systems are # max 1psi. Any more than that will hurt them. You will need to use a regular smoke machine. I used one on a Duramax once. Cranked the pressure all the way up, and it still took 1/2 hour of sitting before any leak showed on the intake pipes. Since that, I went back to soap and water, and to mee that work better.

 

[subway]

i know an exhaust leak killed all my boost when i put it on. i couldent even hear it though since i was just running the down pipe. like mentioned something else to consider.

just asking but would soapy water show much at all without boost at idle?

 

[DeepRoots]

nope, no boost at idle.
you'll need a friend holding the brake and hitting the throttle.

or ummm, south georgia style. drive the truck against a tree. have someone rev the engine in gear.

 

[reklund]

That would work great, if my truck were an automatic!

I'm devising a way to pressurize the IC with regulated shop air...

stay tuned
Ryan

 

[RedTruck]

I remember reading about someone fabbing up a leak down test with air on TDS, but I can't find it.

Paul

 

[Diezel_Cowboy]

You have more air now........so you need more fuel to mix with it. Turn the pump up and check boost again. It takes horsepower to generate boost then the boost can help generate more horsepower (provided fuel is available). Take that sentence in the order you see it.

 

[FordGuy100]

You have more air now........so you need more fuel to mix with it. Turn the pump up and check boost again. It takes horsepower to generate boost then the boost can help generate more horsepower (provided fuel is available). Take that sentence in the order you see it.

I'm pretty sure he has plenty of fuel if he has a DPS pump

 

[reklund]

Checked today for exhaust leaks. NO soot whatsoever around any of the exhaust connections, so I'm pretty confident that I don't have exhaust leaks.

I do still have a DPS pump, but for all I know it's a stocker. Judging by my less-than-stellar experience with the DPS injectors I used to have in the truck, I don't have much faith in the pump. I can roll coal out the pipe still, but it thins out to a light grey haze at full boost, so I may be running out of fuel. Can I tinker with the fuel screw on a supposedly hot-rodded pump and not hurt anything??

I still have to fab up some parts to complete my IC piping pressure test...hopefully I'll have time for that this weekend.

Ryan

 

[Diesel JD]

I remember you said that Ken's pump doubled your boost when you had the 088 turbo and no IC. You're not in the mood to deal with Ken anymore so who cares about his warranty? You won't hurt anything by turning it up some as long as you watch that pyro and boost gauge. In fact flatlander has turned Mel's Moose Pump waaay up. Its just a matter of having enough air to burn all that fuel, and now you do.

 

[Diezel_Cowboy]

Checked today for exhaust leaks. NO soot whatsoever around any of the exhaust connections, so I'm pretty confident that I don't have exhaust leaks.

I do still have a DPS pump, but for all I know it's a stocker. Judging by my less-than-stellar experience with the DPS injectors I used to have in the truck, I don't have much faith in the pump. I can roll coal out the pipe still, but it thins out to a light grey haze at full boost, so I may be running out of fuel. Can I tinker with the fuel screw on a supposedly hot-rodded pump and not hurt anything??

I still have to fab up some parts to complete my IC piping pressure test...hopefully I'll have time for that this weekend.

Ryan

The light grey haze is normal when the turbo kicks in. This is an indication that the extra fuel is being burned rather than spit out the pipes in the form of black smoke. When you turn the pump up you will experience the same thing only there will be even more fuel to burn when the turbo kicks in. I have had the fuel screw on my pump maxed out for years with no ill effects just remember to keep an eye on your pyrometer. Also I have blocked off the waste gate on the turbo.

 

[hesutton]

Checked today for exhaust leaks. NO soot whatsoever around any of the exhaust connections, so I'm pretty confident that I don't have exhaust leaks.

I do still have a DPS pump, but for all I know it's a stocker. Judging by my less-than-stellar experience with the DPS injectors I used to have in the truck, I don't have much faith in the pump. I can roll coal out the pipe still, but it thins out to a light grey haze at full boost, so I may be running out of fuel. Can I tinker with the fuel screw on a supposedly hot-rodded pump and not hurt anything??

I still have to fab up some parts to complete my IC piping pressure test...hopefully I'll have time for that this weekend.

Ryan

Ryan, I've had the same issue from day 1 of driving my truck. The DPS IP and injectors seemed to help, but I'm no where near the limit for boost or EGT's. With the wastegate disabled, I got up to 12 psi and 800 degrees, but that's it. I too can spit soot if I really want to, but mostly, its the grey haze you are having. My wastegate rod is as short as it can get with the adjuster as well.

I emailed Ken and finally got a response. He said to adjust the fuel screws (internal and external) to max, but to "crack" the internal screw back a little from completely bottoming it out. I've not done this, but I may here soon.

My lack of high boost and my low EGT's have keep me from even trying to find or hook up a intercooler as I don't see how I could benefit from it with these numbers.

Also, my EGT's did drop a bit (it's not like they were high before) when I installed the DPS stuff.

Heath