1G Some boost leak questions..

[jgouds]

Hey all, here's my first post! Would have liked to introduce myself as my first post, but a problem has already arose prior to my doing it. I am more familiar with Honda's but got a good deal on an AWD turbo and have been loving it for two-weeks. Anyways...
I was driving yesterday and on a harder than normal pull my car stuttered a little bit and as of then can barely make boost. Parked the car and looked for any pipes that might have blown off, took off a couple suspect pipes and re-attached them to no avail. Turbo spools, blow-off will go off, but the "get thrown back into your seat" feeling when under boost has been replaced with sadness. Max boost I can make under WOT is 10psi, but under pretty much normal driving to what I was driving before I'm peaking at 1-2 PSI. Sorry about the mod list lacking some brand names - Just picked up the car and the owner didn't remember what brands they were and the receipts for them didn't specify.
Here are the mods:
MBC
AFPR
MAF-Translator
Boost gauge
Heavier duty clutch
More aggressive cams
Shep Trans
Ported EVOIII big 16 turbo
Ported 2g O2 housing
Walbro 190 lph pump
550cc injectors

My first instinct is a boost leak test, which I will be doing tonight. I am aware of a small exhaust leak at the manifold, but figure this isn't the cause for the boost issue given the turbo is spooling fine. I took off the intercooler, cleaned it and reattached the pipes and found oil in the upper IC pipe. Not sure if this is blow-by or the turbo was shooting oil everywhere. Vac is around 14 mmHG, which I know is abnormal but have been told cams can cause that. Idle is also at 1000 as opposed to 750 (ISS or leak? Yet to be found out). Anyways:
I plan on doing the test tonight and was wondering if any of the more experienced members can point out some other things to check?

 

[bigdnno98]

do the boost leak test (BLT) and get back with us. you'll more than likely find your issue at that point. DSMLink? logs? any DTC codes?

 

[jgouds]

I am unfamiliar with DTC, but no CEL's yet. And no dsmlink, as I've just picked up the car I'm waiting on a few essential components. Got a Palm with MMCD, just waiting on the ALDL cable and have a wideband waiting to be installed.

 

[1990TSIAWDTALON]

Make sure the MAF is plugged in. My plug came off as I didn't get it pushed on until it clicked and the car hated me. Also make sure the intake pipe is snuggly attached to the turbo with no leaks. This just happened to me, forgot to tighten down the clamp at the turbo inlet after a major teardown. Little things do bad things. Just a couple ideas for you.

 

[jgouds]

Made my boost-leak tester with 3" PVC because I have a 3" MAF and it didn't fit - DOH. Did check the MAF, plugged in all secure. Have yet to check the turbo - that's the first place I'll be going when the car cools down. Thanks for the input. I did find my lower IC hose was pushed off that metal lip on the intercooler so I reattached that last night and it helped quite a bit - but the car isn't quite all there. Just a question to the all those with experience, I'm running 16PSI and have been told to use T-Clamps in favour of hose clamps. Are hose clamps really an issue at 16 PSI? Thanks for the input gentleman

 

[badbird]

T clamps are the better of the two, however a properly installed regular hose clamp will be just fine at 16psi... I had similar issues with my car, I found it to be plugs, replaced them and had then gapped correctly, this got rid of the problem temporarily and it started again, turned out plug wires needed replaced as well. I have also had the issue at hand happen with a small boost leak, normally if it's a bigger leak the car will fall flat on its face. For the BL test get an empty spray bottle and full with dawn dish soap and water, extra bubbly and spray over anything that could leak boost so you can see bubbles from easily over any possible suspects.

 

[jgouds]

I have a bunch of t-clamps just kicking around - I will swap those this weekend and clean up some of the gaskets and put a little RTV on them and report back with changes. I changed the plugs about 2 weeks ago, so I would hope they're still good. Gapped to spec and everything. Hadn't even thought about the plug wires - I will measure their resistance and see if they're still any good. I always thought wires going bad was more of a gradual degredation vs the sudden inability to make boost I'm experiencing. Good tip on the dish soap, thanks for your input!

 

[jgouds]

So I found this in my turbo... so a boost leak isn't alllllwaaaayyys the answer haha. But, does anyone have any idea what this is? Cause I'm sure it isn't good..

 

[1990TSIAWDTALON]

Dam...did that eat up your turbo? Or just block it? I can't think what part that used to be but I'm going to say last rights right now... come on everybody it name that piece time.

 

[phantom_19]

Im pretty sure you planted that in there . Is it metal? Do you still have a turbine wheel? That is really strange. I cant think of any piece that fits. Most likely you have found the problem

 

[1G Eclipse94928]

Im pretty sure you planted that in there . Is it metal? Do you still have a turbine wheel? That is really strange. I cant think of any piece that fits. Most likely you have found the problem

I agree something about that piece of metal is all wrong.. :O

 

[jgouds]

It solved my boosting issue removing it. Definitely did not plant it in there. Didn't touch the turbine which is great. I just have no idea where it came from - it looks way too big to have fit through any of the runners. It had a numbee stamped on it, when I get home I'll post it and see if that helps

 

[1990TSIAWDTALON]

Turbo ID stamped tag??? But how would it get there. Lucky it was kinda thick !!! Header flange separator?

 

[jgouds]

All I could make out was an AE followed by some messed up numbers. Probably not much help. Can't figure it out what that piece might be. I imagine it was some sort of ring before it got crushed

 

[GRAVEDIGGER]

That's crazy! I can't think of what that could be... Wow!

 

[1990TSIAWDTALON]

Man I think we are all amazed that it didn't get to the turbo. Cross your fingers and thank your lucky stars!!! Hey Gravedigger, am I mistaken but is there a "ring" inside some factory exhaust mani's? Could this somehow be that? I thought my sons had some sort of ring inside it but its been to long for me to say yes it did have one. Now we're all just puzzled about what it "was".

 

[GRAVEDIGGER]

Man I think we are all amazed that it didn't get to the turbo. Cross your fingers and thank your lucky stars!!! Hey Gravedigger, am I mistaken but is there a "ring" inside some factory exhaust mani's? Could this somehow be that? I thought my sons had some sort of ring inside it but its been to long for me to say yes it did have one. Now we're all just puzzled about what it "was".

Yeah, I was thinking the same thing, but then I thought "naw, it can't be that", but maybe it is...
I will have to take a look at one of my stock manifolds when I get home.

 

[ErikTande]

It kind of looks like what Jafro found at 8:23 in this video:

You must be logged in to view this image or video.

 

[1990TSIAWDTALON]

Boy if it is/was then something beat the snot out of it, well really no matter what it "was" its amazing it stuck where it did. Let me know if you find out. I think we are out of stock mani's at our place and we have 3 - 1 or 2g's and 2 3G's.

After watching the video on my phone (can't do it here at work, internet police...), Erik that looks eerily similar.......

 

[jgouds]

Yeah that looks pretty much exactly like what I found, apart from mine being a little bit more squished. Hopefully the part is a non-issue having "removed" itself - drivability is better than now than ever, so it would seem all is well. Thanks for all your helpful input guys

 

[evo-gsr]

Looks like the flame ring from the manifold from what I can make out ?

 

[GRAVEDIGGER]

Looks like the flame ring from the manifold from what I can make out ?

That has to be what it is... It's the only thing it can be.

 

[evo-gsr]

Without a doubt thats what it is.

 

[pauleyman]

Man haven't you guys ever taken apart a stock car? That looks like the fire ring. Only problem is youre not supposed to install it on a 7cm housing unless you have the evoiii fire ring and even then it cant be ported. Somebody didnt know what they were doing.