Leaking return lines

[Rabbit on Roids]

my bet would be stuck wastegate. or just plain not enough fuel..

[Smokey Eddy]

that being said, ROR, I would have to say try romping on the pedal in 2nd get her up to 50kmh and then slow down, look behind you and if you have a decent cloud lingering then i'd say wastegate is stuck... which really sucks because i can't get at my wastegate. The nuts that hold the plate on it are fused to the turbo

[rodpaslow]

Well I got the leak stopped on #2 as it wasn't the return line, I guess the steel line wasn,t quite tight enough - oops.  #3 return line is still leaking though, possibly not as bad as it was.

Has anyone ever connected the return lines in the center with a tee going to the pump so it pulls the return fuel from the center?
I think I need to try a couple things yet.  The injector return line between two and three is long, I'm going to shorten and try it again and if that doesn't work I don't know what to do next - connect a larger return line to the tank?

As for the turbo, I'm 99% sure the wastegate is leaking as I'm still only getting about 12 psi max.  Have to pull it and somehow loosen the bolts covering the wastegate (T3)  The bolts look pretty bad, I'm almost sure they will break....

[Smokey Eddy]

I think you're going totally overboard with the leaking injectors to be honest. did you get new rubber line with the braided stuff on the outside? did you take the lines off (the steel ones) and put them back on again?

[Rabbit on Roids]

Well I got the leak stopped on #2 as it wasn't the return line, I guess the steel line wasn,t quite tight enough - oops.  #3 return line is still leaking though, possibly not as bad as it was.

Has anyone ever connected the return lines in the center with a tee going to the pump so it pulls the return fuel from the center?
I think I need to try a couple things yet.  The injector return line between two and three is long, I'm going to shorten and try it again and if that doesn't work I don't know what to do next - connect a larger return line to the tank?

As for the turbo, I'm 99% sure the wastegate is leaking as I'm still only getting about 12 psi max.  Have to pull it and somehow loosen the bolts covering the wastegate (T3)  The bolts look pretty bad, I'm almost sure they will break....

yes, i made mine run to the center with a T.. works fine, looks better too.

as for the waste gate being stuck, just spray some oil on the shaft going into the housing, then grab it with some vice grips, and work it back and forth a little.. they usually free up from the outside too. throw a little torch at it if its a b!tch to work, heat the shaft up, not the actuator rod.

if that doesnt work, then take the wastegate cover bolts off. might have to hit them with heat and oil pultiple times, but they should come apart.

[rodpaslow]

I guess I should start with the issue, I can romp on the car in second or third and there is a rather large cloud of smoke  behind me - no problem there!  I had a rather good coating of black inside my 2.5 exhaust, so I don't think fuel is a problem - still only 12 psi boost at least 4000+ rpm.  She hits about 12psi at around 3000 rpm and won't go any higher.(reading t'd into fuel enrichment line)

So I pulled the turbo out this afternoon and I was able to loosen and remove the plate that covers the wastegate valve.  I can get it to turn, it makes a sandy type of sound as you turn it so for the most part I think it's seated.

What's the next step?  I have the pressure line that goes to the turbo tee'd off an open to the atmosphere. (5/16" dia line).  Is this sufficient to bleed off enough air or do I need to plug it so there's no way the wastegate will open and test it.  I can't see how to remove the wastegate, I'm not sure this would tell me anything.  I'd like to be able to hit 20 psi with this t3.

What is the line just before the intake of the turbo for?  Is this to help bleed off pressure too?  It seem like there connected to each other.

[dokarex]

Has anything been done to turn up the boost on your turbo, you don't say if there was? If you have the external adjusting (check out the FAQ and search for how to make a 1.9TD a faster car, or tuning a 1.9td) arm move the outside nut 1 to 1-1/2 turns outwards then tighten the inner nut out towards the outer nut and see if there is more boost. If you don't have the external arm there is a way to raise your boost but I haven't done it (I have the external arm)

[rodpaslow]

I wish there was an external adjustment, that would make it easy.  By what I've read I always thought it was bleeding, or letting air bypass the wastegate controller as the boost increases. 

I've left mine totally open and still only 12 psi max.  I have it out of the car, maybe I'll take a picture and post it, but I'm pretty sure it's a standard T3.

[rodpaslow]

I've read a T3 can support 20 psi without too much trouble.  I'm not sure where I'm loosing the boost.  The boost lines use t=bolts so I' don't think it's there.  I think the wastegate is opening or stuck open (maybe) because it's stopping at 12 psi.

I can add a picture I'm not sure http://pxt.virginmobile.ca/view/album/details.do?lsdb=7&elementID=3087256321&subretailerid=VMC&nameSpace=VMC&containerID=1391706113&page=1&retailerid=VMC if this works.

[rodpaslow]

http://pxt.virginmobile.ca/view/album/details.do?containerID=1391706113&elementID=3087245953&page=2

end view

[rodpaslow]

I had one more thought.  Is there a chance the wastegate spring has weakened and that exhaust pressure at a certain point is opening it?

[Rabbit on Roids]

I had one more thought.  Is there a chance the wastegate spring has weakened and that exhaust pressure at a certain point is opening it?

the wastegate can be opened by exhaust anyway, even operating normally.. they blow open at about 25 psi.. yours is probably just stuck.

[rodpaslow]

This may be a stupid question, but can the canister/control of the wastegate valve be removed/cut off and a adjustable one installed? 

I know this has had many,many miles on it (car I got this from had 500,000 km+).  I've had it out of the car twice and I can't seem to move it open, but I can turn the actual valve with a metric allen key.  So I'm assuming it's opening at 12psi.  I absolutely have no leaking (my outlet to the exhaust leaks a bit, but that has nothing to do with turbo issues, right?).  I'm putting it together today and take it for another run and see if there's any difference.  This time I removed the hose totally from the wastegate cannister and plugged the line.  We'll see what happens...

[rodpaslow]

Before I put the turbo back in, I drilled a hole for a small bolt to test and see if the wastegate was opening at 12 psi.  I threaded the small hole that I drilled.  This covers the wastegate valve on the T3, so I could adjust it later if, in fact, it was in fact opening.  I screwed the bolt in so it was holding the wastegate closed.  I hit 20 psi at about 3500 rpm, 120 km/h (75 mph) in 5th.  It's awesome.

Just wanted to thank all that responded, all has been fixed.  The return leak has been fixed as well.  I think now that fluid has been flowing through it, whatever remained in the line as a part blockage has dislodged and gone back into the tank - hopefully.