Archived Intercooler?

[GadgettR1]

Recently noticed a "rushing air" noise and lose of power from my 01 auto. I found the air noise (loose clamp and intake boot into the airbox was partially off). But I still felt like I had a loss in power and I was blowing alot more smoke than normal when the comp was on (not tapped). So I dropped it off at the dealer (didn't have the time to play with it myself. . work). They think that the intercooler is blocked? Is that possible or do I have a bad boot somewhere that I didn't notice? I do think it still sounds a bit "off" but I don't have the rushing air sounds nearly as bad as I did before. No I don't have gauges installed. . (have them here in the closet just waiting for a few more pieces then someone to help me put them in. . ).



Thanks for any advice



Chip

-- email address removed --

 

[lmills]

Sounds like a boost leak somewhere. I doubt it is the intercooler unless it has a whole in it. Their is a kit that you can buy to put compressed air into the system to check for leaks. I believe it is listed in the classified in the TDR /Basement vendor section. You can also make a set with 4" PVC pieces and some air fittings

 

[Andy Redmond]

Chip



Usually an innercooler will leak, not be blocked. If its blocked contaminents /debris have entered it or it has a piece that has collasped/broken internally. . pretty rare unless you've experienced front damage from an accident. Unless it was actually opened from the charge air clamp you mentioned any debris would have passed thru the turbo, likely grenading it. .



I would ask for the technician notes on the RO or a better explanation. BTW used or good aftermarket innercoolers are available for about 1/2 the dealer price, unless its under warranty.



Readsearch in the second gen 12v forum about the homemade "fernco" testers many of us have assy for reasonable $$ to test for leaks. . You will need a small air compressor too. .



My bet is a boost leak, bad wastegate or maybe a leaking innercooler. Let us know what your find. .



Andy

 

[GadgettR1]

Ok guys thanks for the advice... I'm going to call them from work and see what they have to say. I didn't really think an intercooler could just block up like they think it is. I should of just tried to find the time and taken a better look at it myself. .



Chip

-- email address removed --

 

[GadgettR1]

Ok so the dealer says it's not the intercooler but the wastegate and that I need a new turbo. So from my understanding. . the wastegate I assume is stuck closed? (I'm getting no power and lots of smoke so I'm not getting any turbo air. . correct?). So now my questions are: 1. can't the wastegate be held open (I believe there were some type of clamps for sale to do this so autos could get more boost. . would that solve my problem for now?); 2. can the wastegate be replaced or rebuilt?; 3. Will a turbo off a standard transmission truck ie hx-35 bolt right on for my 01 auto? 4. Will a 01 6speed HO turbo bolt right on? (there was one for sale in the forum)?



Thanks



Chip

-- email address removed --



PS

What will I need to do the swap? I don't think I'll be taking it back to the dealer for the turbo change out if I can do it myself.

 

[Andy Redmond]

If you are out of warranty. . Call Blue Chip in Southern NH or Mass Diesel (s/b) pretty close to you, you are out on the cape, right?



What is happening is that your wastegate actuator is not closing (ie sticking open partially open) completely allowing boost you need to bleed off. A crude example is the flapper in your toliet tank that is attached to the chaing, when it leaks water or won't close when flushed. The idea of the wastegate is to "pop" off and dump some of the boost when 20 psi or so is reached to prevent overboost and turbo overspeeding, but yet a small housing to provide quick spoolup for throttle response and emmisions purposes.



If the rubber diaphram in the wastegate will allow for manual closing you could add a "j-hook" as sold by TST, PDR and others. This is simply adding a bigger spring to delay the wastegate opening. $35. If you are not running any power inhancements this will increase egt's and likely set a trouble code or the electronics will defuel and derate power based on the "overboost" condition.



Parts for yours. . contact the above or find a local holset dealer/distrib. The vendors above may have a core turbo takem off another truck to part out to you. . The wastegate is not rebuildable. .



Yes, the other turbos should work. . Pre-99 dodge hx35w apps, will require you to remove the bolted on tailhousing/elbow assy from your HY and you would reuse it on the earlier model turbohousing.



You will need a turbohousing to exh . manifold gasket and a turbo/exhaust flange gasket so everything reseals properly.



Your dealer scares me. . they have gone from a blocked innercooler to a bad wastegate actuator? So what is the real problem? The wastegate being as they describe can cause your complaint.



Let us know. . Andy

 

[GadgettR1]

Thanks Andy. . I picked up a turnbuckle and some parts today at Home Depot and will try them tommorrow after work when my truck is cool. You said the pre 99 turbos need to change pieces. . does that mean the post 99 turbos will bolt right in with no changes? Even if it's off a standard transmission?



Thanks



Chip

-- email address removed --

 

[motohead84]

Check your email. I sent you a pic that edge sent to me of the turnbuckle install on the turbo. I too had the 01 auto. It worked great, but i just wanted to develop more boost. I suggest finishing the install of the gauges to monitor the boost.



Hope it helps

Andrew

 

[GadgettR1]

Thanks. . yes the gauge install is definatley moving up in my list of things to do... .

 

[Andy Redmond]

Yes, and the ETC engine options will usually have a 12cm2 turbo housing which is a bit larger than your oem unit.

 

[GadgettR1]

There are several used turbos close to one another in price range. Am I better off going with a PDR modified HY-35 or a stock Hx-35 off a HO 6speed? My 01 auto has an Edge comp (no pierced... yet) and will soon have a 4" exhaust. Hopefully in the future after a tc and valve body I'll do stage 2 injectors. Until I can afford to get the transmission fully done then I'll add the big parts. So I guess my question is which is better a PDRHY-35 a Hx-35 or a stock Hy-35?



Chip

 

[GadgettR1]

Well thanks for all the help from everyone. I "buckled" the wastegate and now she seems to run much better if not as good as she did before. I figure that's only tempo though so I'm looking for a replacement turbo. Just not sure if I should just go with a Hx-35 or another Hy or just go all out and buy one of the used PDR40's that are around for sale. Any suggestions?



Chip



thanks again for the help