Boost Problem Found.

[radixr]

I had experienced a loss of maximum boost after the installation of governor springs and could not find a reason. I remembered a post by Evan Beck (I think) in which he stated that 75% of the trucks he saw with boost problems had a boost leak. I did not think this was the cause of my problem because it happened after the installation of governor springs.



I finally got around to checking for boost leaks. Turns out an intake manifold bolt was missing -- major boost leak!!!



Moral of the story: checking for boost leaks should be a part of your regular maintainence schedule.

 

[Strick-9]

I've been there. I lost a LOT of boost and fought the problem for 5 months.



I finally broke down and built a device to charge the intake system with compressed air a few weeks ago.



I too had a missing manifold bolt along with a leaking air intake gasket. That was good for 14 psi of boost. I went from 32 psi up to 46 psi.



I thought with the high CFM airflow of our engines a little leak wouldn't significantly affect boost. Boy was I wrong.



-Chris

 

[Alaskaskiff]

Boost Loss - Wastegate actuator

I was down 4-5 pounds of boost due to a blown bellows in the wastegate actuator. I found it by making up a pressure tester (regulated to 20 pounds) with a piece a 1/4 inch air hose hooked into actuator line. New actuator fixed problem (cummins p/n 3536211)

 

[R.ebel]

strick-9,

Could you possibly describe or post some pictures of the device you constructed to pressurize you intake system? I think I have a few leaks



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[Dave Remillard]

Hey Strick-9, I'm with R. ebel on asking for more info. or pics. I purchased my rig new in 95, but it's only recently that I've have felt the urge to do more with it. Finding any present problems first will help in determining what comes next. Thanks for any extra information you have.

 

[radixr]

Pressurize boost system.

Here's what I did: Went to Home Depot and bought a 4" PVC end cap and plug. Drilled and tapped the plug for a 1/4" NPT air hose fitting and a 1/8" NPT hole for a pressure gauge. I removed the end of the hose from the air cleaner and fastened the hose to the PVC end cap (I removed the air cleaner first).



Unfortunately, this hose doesn't take air pressure very well and I could only build up a few psi (the hose wants to expand it's length). However, this was enough to find big leaks.



Home Depot also has 4" heavy duty rubber sewer line connections. A better idea might be to remove the hose at the turbo inlet and use the rubber connector to attach the PVC end cap to the turbo inlet. Now the pressure build-up would be limited only to how much can the rubber connector take. I have the rubber connector but I haven't tried this yet.



Update: I just tried the 4" rubber sewer line connector. It works fine except I only went up to 12 psi. The rubber sewer line connector was bulging some and that was plenty of pressure to test for leaks. I did find another small leak at the turbo boost control elbow (near the AFC housing).

 

[Strick-9]

Sorry for the delay guys.



I did something very similar to radixr, but on the pressure side of the turbo instead of the intake side.



I removed the 90° elbow coming out of the turbo before the intercooler. It only requires removing two hose clamps. I left the rubber connector on the intercooler pipe and stuffed a PVC end cap inside the rubber connector and hose clamped it.



The PVC end cap was drilled and tapped for 1/4" NPT threads and had a quick coupler installed in it.



I then applied 20 psi of air pressure to it. You could hear the leaks immediately.



Those rubber connections expand a LOT with 20 psi of pressure, I can't imagine what it does with 46.



I don't know exactly what sized cap it took. I would guess 2. 5".

It wasn't a great fit, but I had it laying around and it worked.



Hope that helps.

-Chris

 

[cumminsgetme]

Chris

Where are you ??? I sent you a pm... ... . give me a call. 979 575 5647. We need to get together some weekend and tinker with our trucks.