Engine/Transmission (1994 - 1998) Boost leaks

[nfox]

How is the best way to check the intercooler and piping for any leaks? I was thinking about unhooking the intercooler hose off of the turbo and getting a pvc union and cap and clamp that on to the intercooler tube and do the same on the intake side and put a air fitting in one of the pvc caps and try to pressurise the system, and spray it with water, will this work or am i thinking wrong?

 

[Deezul1]

Put a tire fill stem in the system you describe and a gauge and then watch the gauge for bleed off and then look for the leak.

 

[illflem]

The method Deezul recommends works well. Just don't try to pressurize the system though the hose from the airbox to turbo. It's not designed for pressure, tried doing it that way once but had to come to an emergency stop at 10 psi when the hose expanded to twice it's normal size.

 

[rbarr]

I was checking a Cat's 3406 E intercooler like that the other day and blew one of the endcaps threw the windshield. That stinks. It is a very good way to check the piping but make sure your clamps are TIGHT!!!

 

[chrleb1]

I like to take a 4 inch piece of hose and put a 3 1/2 inch pvc cap in it. Then I drill and tap the cap to 1/4 pipe thread so I can put a air fitting in it. Then clamp the hose onto the turbo inlet (also clamp the cap into the hose). This setup will test all of your hose connections and your intercooler. You can easily hear a leak when you have the air tank of your compressor at 25 - 30 psi.

 

[nfox]

4" Hose

Where can i get a piece of 4" hose to clamp on to my turbo and presurise my intercooler?

 

[illflem]

Re: 4" Hose

Originally posted by nfox

Where can i get a piece of 4" hose to clamp on to my turbo and presurise my intercooler?

The rubber couplers that most hardware stores sell for drain pipe work well. Comes with the clamps. Take measurements, the couplers are available in all different sizes, and even with a different size on each end.

 

[nfox]

I pressure tested my intercooler system and found no leaks. So i thought, what if i pinch off the wastegate line and drive it and see what happends, bingo that is what the problem was. Time for a boost elbow.

 

[Woodenhead]

NFOX



What made you want to check for leaks in the first place? Are you getting low boost? I have a very similar setup to you and used to be able to hit 36 psi (PDR HX40 wastegate) without a problem. Now it seems like it'll just barely get there if at all, seems to have a hard time getting past 34/35psi. I chalked it up the 100deg heat outside, AC on blah blah but in the back of my head I'm wondering if I got leaks.



What's the deal with the boost elbow? On my PDR HX40 the waste gate is pre set at 36psi and is hooked up straight from the compresor housing. Do you need more than 36psi boost? Why not adjust the waste gate?



Now ya got me thinkin



Mike

 

[nfox]

Boost PSI

After breaking in my new PDR HX40-16, my max boost was about 28 to 29psi. I talked to piers and he said it was wastegated at 38psi. They told me to pressurize my air system to check for leaks, and there was none. Then i decided to pinch the wastegate line to see if it changed my boost any, and now it will go up 39 psi like a rocket. The he told me at that if i didn't have any boost leaks that i would have to install a boost elbow and set it so it will not go over 38psi of boost. Oo.

 

[Woodenhead]

I guess I got my numbers mixed up, 38 not 36. Looks like I've got a similar deal. Like yourself I guess I should put my boost elbow back in and mess with it. Why won't it go over 29 psi? The wast gate must be opening at less that 38 psi (like 29 for yours) Why not adjust the wastegate? Is it difficult to do (I've never done it).



Mike

 

[ramman]

I had a similar loss of boost also with a PDR hx-40 my problem was a leaking manifold to turbo gasket. While rappimg the throttle under the hood I say a small puff of smoke I couldn't believe it was a large enough leak but it was my #10 boost that was lost,also check the manifold bolts any loss of pressure in the exhaust will kill your boost.

 

[nfox]

I will check that out also with the truck running and see if the manifold is leaking anywhere. Thanks!!