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Engine/Transmission (1994 - 1998) Studied Wastegate Settings Tonight--Problems!!!

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Engine/Transmission (1994 - 1998) Injector Choice

Engine/Transmission (1994 - 1998) Interesting find

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After I just got the transmission taken care of, I thought I would try and optimize the stock turbo configuration for my truck by just playing around with the wastegate. Where the gate was set (never touched it since I got the truck with just the #6 plate kit, I had my boost elbow screwed all most all the way out and I could go past 42 lbs on the gauge if I wanted to. :eek: I thought I would try to tame it down to around 30 or so with the gate, then fine tune it up with the elbow. I had read on here that 1 turn equals ~3 psi. So I went and gave it 5 turns to see what I would get out of that. Took the truck out for a drive. Right away I notice a lot more lag, for some reason, and the smoke that I see a lot of people get with bigger housings on there turbo. It literally looked like I was trying to spool up while dragging a sled. The most smoke I have seen out of that truck. Also I lost the turbo whistle that I had before. I know it sounds stupid but before I could even get about 15 lbs in park revving the throttle, and I could here that whistle. Boost was definately lower in park than it was before. On the highway, taking it easy slowly accelerating, I glance at the pyro and it showed about 1000° pre-turbo. I thought WTF. So I get it up to highway speed, set the cruise, and I notice the gauge slowly getting down to about 800°. I thought that was decent, but the high EGT at part-throttle really got me. Then I went WOT and noticed the gauge climbed a lot slower and I could get up to about 90 or so and the gauge was at a respectable level, around 1400°. Boost was still up at 38 lbs. So just for curiousity I brought the truck back to the shop and tried to tune the boost down to around 30 lbs or so. Turned the rod out two more turns and buttoned everything back up. So 7 total turns from where I had it. By this time it had just gotten dark out so I couldn't tell the smoke effect. The lag was still there of course, and hadn't changed at all. This time EGT's climbed even slower yet, and I could only hit 33 lbs of boost on the gauge. But with the slower climbing EGT's, I also loose the response in all rpm and speed ranges. It seriously feels like I put a different exhaust housing on the turbo. Reminds me of one of Jim Fulmer's dyno videos exactly, while spooling up. A bit less smoke though. :-laf



Can we come to any conclusions on this as to why the adjustments affected the performance that much? I really don't know where to set it. I really miss the response of the old setting. And I thought I would have gotten a bigger change of boost than I did in each turn of the actuating rod. Any recommendations?
 
you want to adjust boost via the elbow, not the wastegate in this situation. if you're opening up the wastegate early, then you're losing a lot of that exhaust gas engery used to spin the turbo. less engery=less turbo spin= less boost/air=higher egts. tighten up the elbow until you're reaching about 35psi (most efficient # on a stock HX35 turbo--over that is starting to create too much heat in the intake side). also, if AFC housing on top of the injection pump isn't seeing much boost, then the rack stop inside the afc housing will not move forward far. essentially it's holding back the fuel to the point that it doesn't hit the plate. seems like you're ready to upgrade the turbo at this point, or back down the fuel... need more volume of air, not psi. sometimes you can find HX40's pretty cheap on ebay.
 
What i'm wondering is why did it take so many turns on the rod to lower the boost such a small amount. If 1 turn equalled 3 psi like I read, I should be down to about 25 psi then. And how come adjusting the wastegate gave me a ton more lag? I had thought about putting a different housing on the turbo. With the lag I had I don't even know if I want to put a bigger turbo on. Something just isn't right. I'd rather have it the way it was and have it harder on the turbo than have the crazy lag and high mid-range temps that I have now. I was just trying to control the boost, if for some reason I have to hold the throttle at WOT without having to let off for fear of trashing the turbo.
 
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Try and go back the other way a little bit with the adjustment. It sounds like your wastegate is opening way to early. I would mainly set the wastegate off the elbow and not the rod. If the wastegate opens too early, you will tons of lag and it will take a ton of fuel to keep it going.
 
It would work to just raise it with the elbow, wouldn't it? I think I will try that.



I notice it also takes longer to reach the peak boost level than it did before, so you could be right about it opening to early. About the only answer to that, to keep the boost level down but yet not dump the air early, is to get a bigger turbo.



I love the kick it has when it spools now, just like a big turbo. I just miss the quick response it had before. Also now at 60 mph i'm running at 850° pre-turbo compared to the ~<700° temps I was seeing before. It rises to about 1200° on normal acceleration up to 60 mph then falls down to 850° at 60 mph on cruise.
 
like said, don't adjust it via wastegate. only start doing that when you're running high boost and/or twin turbo applications. put the wastegate back to it's original setting. use the elbow, and bring the boost down to about 35psi.



your wastegate is opening too early, allowing exhaust gas to flow right by the exhaust turbine. the exhaust turbine has less energy now, which slows down the shaft speed of the turbo. when the shaft speed slows down, boost declines. less boost per the same amount of fuel equals more heat and visa versa (provided that higher boost isn't getting too much hotter since compressing air creates heat). you want to hit 35psi of boost, and THEN let the wastegate open, NOT starting to open below 35psi.



Tom
 
Got ya... .



You're last paragraph really made it hit me. I just couldn't picture it right, your description was perfect.



I planned on trying to turn the elbow screw in today but I tried and it was turned in all of the way. That probably didn't help for adjusting.



So what I need is a regulator inline when setting the gate to allow a certain amount of pressure to the diaphragm. So I should adjust the lever so it just starts to move when the desired pressure is put in? Around 19 PSI regulated pressure?
 
Just an update. The wastegate was set to open too early, or was just plain set open. I also found that my actuator is bad. So I plan on setting the arm so it holds the gate closed in the meantime, and am planning on ordering a TurboMaster in place of the stock setup.
 
TMaas;

My repair manual says to use compressed air to set the opening of the waste gate, just enough air to start to open, and use an accurate Gage. That little "c" clip must be a real bare to replace each time.

just my penny's worth.

Marv.
 
Tmass if you need a hand with anything or just wanna shoot the breez im up in willmar and am very god with these trucks. shoot me a pm sometime.



The Fat Kid

Andy
 
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