given up. still surges and a max boost of 5 psi

[billyfusco]

hello all. i have replaced the isc, throttle body gaskets/shaft seals, injector o-ring & isolators, and it still surges. I am going nuts trying to figure out the surge problem. When i push the clutch in it idles at 1100-1200 rpm until i am completely stopped. Then it will idle down to 900 rpm.

As for boost....nothing more than 5 psi. I was boosting at the stock 9 psi the day before i changed the TB shaft seal. I checked for shafts play and it seems fine. I will be blocking off the EGR today and removing/blocking off the vacuum lines.

I did do a boost leak test and it will holds 15 psi well. I can not hear anything or see anything when it is sprayed down. When i start my car i have about 12 Hg of vacuum. When it gets to operating temperature it's at 0-2 Hg with no more vacuum than that.

Please help me

 

[ddavisaf]

Check the injector seals and the intake manifold gasket for boost leaks. Also check your pcv valve for proper operation.
Make sure you don't have an exhaust leak before the turbo.
Post back

 

[BudmannG]

Make sure you don't have an exhaust leak before the turbo.

What will this cause the car to do, idle surge?

 

[ddavisaf]

Turbo lag, less boost.

 

[billyfusco]

Checked the injectors already. As for the pcv, it's a few months old i can blow air both ways. I went to Canadian tire to get a new one, and i can do the same with all of them. I just installed a new gasket a few months ago when i installed the 2g manifold and new O2 housing. but I will check the exhaust manifold for leaks when i get home.

What would cause the lack of vacuum? A leak in the lines somewhere?????

 

[ddavisaf]

Goto an OEM dealership and get a pcv valve that's good. They are one way valves.

What would cause the lack of vacuum? A leak in the lines somewhere?????

A boost leak

 

[akdsmer]

As for boost....nothing more than 5 psi. I was boosting at the stock 9 psi the day before i changed the TB shaft seal. I checked for shafts play and it seems fine. I will be blocking off the EGR today and removing/blocking off the vacuum lines.

Have you removed the wastegate actuator and verified that it is not open? I've had one with a bad actuator that was stuck open and got very little boost.


I did do a boost leak test and it will holds 15 psi well. I can not hear anything or see anything when it is sprayed down. When i start my car i have about 12 Hg of vacuum. When it gets to operating temperature it's at 0-2 Hg with no more vacuum than that.

If your vehicle is running well (except for the surge) at idle, you shouldn't have very low vacuum. I haven't seen a car under 10" in forever. I have around 18 Hg at idle. I suspect that you are not checking it at a manifold vacuum port. Find a port such as the fuel pressure regulator solenoid which is located on the intake manifold AFTER the throttle body, or adapt into the Brake booster line at the back of the intake which is a kinda a pain to come up with a reducer.

 

[billyfusco]

replaced the vacumm lines and nothing has changed. i still only have 2 in HG.
But just realized when i started the car that the intake wasn't sucking in much air, basicaly nothing. Should you be able to spool the turbo at a stand still with the cutch in??? I have never been able to spool the turbo with the clutch in. I can spin the turbine by hand, and there is no shafts play. It still only boosts up to 5 psi, but very slowly.

 

[billyfusco]

replaced the vacumm lines and nothing has changed. i still only have 2 in HG.
But just realized when i started the car that the intake wasn't sucking in much air, basicaly nothing. Should you be able to spool the turbo at a stand still with the cutch in??? I have never been able to spool the turbo with the clutch in. I can spin the turbine by hand, and there is no shafts play. It still only boosts up to 5 psi, but very slowly.

 

[BudmannG]

This is a link to do a proper Boost Leak Test http://www.vfaq.com/mods/ICtester.html
And here is a link to Boost Gauge Install http://www.vfaq.com/mods/wayback/BradBauer/gauges/boost.html
I just put these up so you can double check and make sure you have it right. Something is not hooked up right or you have major Boost Leak. Double and triple the times you boost leak test. I had found numorous boost leaks injector seals and insulators, throttle body gaskets, throttle body shaft seals, pcv valve, And pin holes in my inner cooler. So continuosly boost leak test until you are positive there are no more leaks.