Car will not make boost. Need some help

[Sprayer84]

The throttlebody doesn't actually fully close and you will have leak by into the manifold and the rest of the engine.

That's what I was counting on. That way I could check the intake/lines as well

 

[JeremyH]

That's what I was counting on. That way I could check the intake/lines as well

You wont be able to find leaks/hold pressure in the cold side properly as you will bleed the air due to open valves, piston rings and exhaust etc.

 

[Sprayer84]

Found a pinhole in the intercooler but not big enough to cause this issue

 

[one eyed willy]

That's what I was counting on. That way I could check the intake/lines as well

Only if you remove the cams...

 

[Sprayer84]

http://youtu.be/NcWGcN--GFA

 

[weather man]

http://youtu.be/NcWGcN--GFA

Since I have the same one sitting in my shed, how do you tell if it is not obstructing flow?

 

[Sprayer84]

It would be really hard to tell because you won't be able to push the volume of air through that intercooler that your turbo is going to push.

 

[Sprayer84]

The intercooler manufacturer also claims only a .5 PSI drop across the intercooler at 15 psi. So I don't believe flow should be an issue. I'm going to start putting my attention in other directions. I'm also going to find somebody to Weld this pinhole up so I don't have to deal with replacing this one and having the new one coated.

 

[JeremyH]

Any radiator shop or aluminum welder can fix that pin hole for ya. It would be a pretty gross manufacturing error for an intercooler to restrict that much flow.

 

[CPRsm]

The intercooler manufacturer also claims only a .5 PSI drop across the intercooler at 15 psi.

It's possible, jist depends what the cfm rating was at those numbers. Pressurize something to 15psi and don't move any air thru the core, 0 pressure drop right? Speed it up, that's when pressure drop means something. So if it has 1psi drop at 10psi but it was flowing 700cfm, not bad. As long as it has the fin contact to keep inlets cool. Other companies will claim a highly efficient cooler because it flows 1800cfm!! But, it's a vertical core and 5 inches tall. It could cool down your breathe if you blew thru it. So you get an idea of the bullshit.

How big is the intercooler core? Dimesnionally.

I wish CPRsm would comment if this is something he has seen on a Chinese intercooler.

No sweat dude, just PM me. I don't catch them all. Especially in a section like this. I just don't visit much.

I noticed today the boost goes up to 7 where I want it then drops to 4?

Is the controller hooked back up again? If tou have the gate pressure set to 7psi and duty cycle set low it would do this. No boost in first can be normal depending on because of lower load. But doubt that's the problem here.

Sounds like maybe the signal line to the BOV is leaking. Won't show in a soke test unless you did the engine. A leak there will unseal the BOV.

Kinda doubt the IC is that big of a restriction, especially chinese version. They usually flow well because of the lack of fin density. If it is a restriction and you see the pressure drop you are, that can push a BOV open as well the charge tube sees 15psi and the intake is only providing 4psi to help keep it shut. If this is the case a line from the compressor housing to the BOV would show it. The extra pressure would keep it it shut. But BE CAREFUL, it will try to surge its fucking head off. Ease off the throttle and let the engine eat the pressure, don't snapp off of it.

If you can and want to know, drill and tap a hole on the tank after the core, pit the boost guage there and compare to the compressor reading. That will tell you the pressure drop and if it's restrictive.

 

[Sprayer84]

It's possible, jist depends what the cfm rating was at those numbers. Pressurize something to 15psi and don't move any air thru the core, 0 pressure drop right? Speed it up, that's when pressure drop means something. So if it has 1psi drop at 10psi but it was flowing 700cfm, not bad. As long as it has the fin contact to keep inlets cool. Other companies will claim a highly efficient cooler because it flows 1800cfm!! But, it's a vertical core and 5 inches tall. It could cool down your breathe if you blew thru it. So you get an idea of the bullshit.

How big is the intercooler core? Dimesnionally.


No sweat dude, just PM me. I don't catch them all. Especially in a section like this. I just don't visit much.


Is the controller hooked back up again? If tou have the gate pressure set to 7psi and duty cycle set low it would do this. No boost in first can be normal depending on because of lower load. But doubt that's the problem here.

Sounds like maybe the signal line to the BOV is leaking. Won't show in a soke test unless you did the engine. A leak there will unseal the BOV.

Kinda doubt the IC is that big of a restriction, especially chinese version. They usually flow well because of the lack of fin density. If it is a restriction and you see the pressure drop you are, that can push a BOV open as well the charge tube sees 15psi and the intake is only providing 4psi to help keep it shut. If this is the case a line from the compressor housing to the BOV would show it. The extra pressure would keep it it shut. But BE CAREFUL, it will try to surge its fucking head off. Ease off the throttle and let the engine eat the pressure, don't snapp off of it.

If you can and want to know, drill and tap a hole on the tank after the core, pit the boost guage there and compare to the compressor reading. That will tell you the pressure drop and if it's restrictive.

It is a CX Racing intercooler, the core is 18x11x3. Right now the boost controller is not hooked up. Running wastegate spring only, 7psi. As of now, I'm getting about 18psi at the compressor housing and a steady 5psi at the I take. Wouldn't it have to be a pretty large leak to drop that much? Is it possible to pass the leak test with my boost tester but leak under the higher cfm's that the turbo puts out?

 

[CPRsm]

ZOMFGD son of a bitch take that piece of shit off LOL. That's your problem. You core is not 18x11. It's 36x5.5, does that make sense? The flow path isn't actually 11in tall. It's only 5.5, but it's also not 18in long. Being that long, short and only 3in wide is a gargantuan restriction. Bypass it and if it doesn't drastically improve I'll have a stroke.
This is where you punch the person in the face who rated it at .5psi drop. You're more like 10psi drop at 17.

Edit: Let's not blame all the drop on the cooler even if it is causing it indirectly. Thisnis the perfect storm I was talking about for the BOV not to see enough help from the intake pressure to keep it closed. Although you have 7psi, so you're probably fine there in reality.

 

[05stroker]

You need a real intercooler....

 

[Sprayer84]

For a new intercooler I'd basically need an entirely new cold side. Maybe I'll try the bypass to see what happens before I have this one fixed.

 

[CPRsm]

You're gonna need a new coldside man. Only way to do same side in and out and not restrict it is w a vertical cooler. On low 7-9psi you could make one work

 

[michael.konor]

Instead of a new cold side, take a look at the hellion intercoolers for ideas that you could get from them, or source from somewhere else:

http://www.hellionpowersystems.com/index.php/hellion-store/153-coolers

I'm using one and haven't had any problem with getting any PSI I want to the intake.

 

[Sprayer84]

You're gonna need a new coldside man. Only way to do same side in and out and not restrict it is w a vertical cooler. On low 7-9psi you could make one work

I'm only going to run 9psi. $900 for a hellion intercooler!? Holy f@-)&$ s@);!

 

[Zimmers]

Same intercooler 9 psi 467rwhp/467 torque. http://youtu.be/_GasDBM5LCQ. We also have this intercooler on multiple other cars without any problems. Can you shine a light down in that intercooler and make sure there's not a rag or something stuffed in it from where you had it powdercoated?

 

[Sprayer84]

The inlets are pretty big so you can see right inside that there's no obstructions on the inlet/outlet side at least.

 

[Sprayer84]

At 9psi it only made 467? I'm pretty sure it's a boost leak issue but my main question is still this. Is it possible that there is a leak under the higher flow from the turbo that won't show up while pressurizing the system with my boost leak tester.