I've recently got my complete mkturbo intercooler plus electronics kit in my vehicle. I performed all the basics to get it up and running good and in boost. I have EBC set up properly, brought it to get it dyno tuned. We went through the whole fuel load range on the dyno. Did a power run on wastegate pressure to confirm everything is functioning as it should. Then when it came time to turn up the boost and start making some more power the most we could get out of the system was approx 10.5lbs. 40% duty gave 10.5 60% duty have 10.5, 80% duty gave 10.5 and 100% duty on the EBC gave 10.5, confirmed this by watching the wastegate actuator it is holding shut the whole time no movement at all. These were all done back to back pulls and all made within 2hp/2tq of each other each time. Looking for suggestions as to what the experts think is going on. Is the turbosmart blow off valve a knock off one that comes with the kit and is leaking boost off, or is the intercooler just too restrictive causing that to be the max number it's capable of?

 

melted cat or boost leak, assuming that the engine is working as it should.

Dann

 

Build a cheap boost leak tester.

 

 

No emissions regulations where I am, I remove cats as soon as I purchase the vehicles. I believe at work we have a boost leak tester with various sizes for testing for boost leaks on Cummins as well as 3.0 eco diesel (work at a dodge dealer).

 

Sounds like a boost leak. My friend had an MK turbo kit and had thenopposute problem. It wouldn't make less than 14psi up top.

 

Could you possibly send me a link to which seal you ordered if it's still available

 

Sure, here you go: T3 Turbocharger Compressor Housing Gasket

There's also at least 2 of the bolts that hold the compressor on that extend into the compressor. I used teflon tape to seal the threads on those bolts. Don't over tighten them as they strip easy.

 

Yeah I notice 3 on mine that go through, thanks again

 

photo328.jpg so I found out where all my boost is going, the flapper on the turbo does not line up with the wastegate hole one little bit. Also found a couple spots where boost is coming through some welds and the where the turbo compressor housing mates to chra.
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Does anyone have any ideas on the wastegate for how to fix it?photo491.jpg it turns out that this shaft can slide up and down freely as it chooses (or as gravity pushes it down)

 

Gotta love the boost leak tester.

Yeah, that arm should not slide up and down. I would assume there should be a C clip on it or something to retain it in place. Though i don't know exactly how these turbos work, i do know that's not right.

 

No c clip and no groove for one to sit in, I'm going to see what clips I have laying around and make my own groove to make it stay up

 

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And problem solved, gently used a cut-off disc and made a groove then fouls and e-clip that fit around it nicely. need to re-assemble and will report back incase anyone else runs into the issue.