Author Topic: turbo questions/running questions (Read 4755 times)

nogama3 · « **on:** May 21, 2007, 05:06:31 am »

Guys, i have a golf mk3 td currently without an intercooler attached and the car runs fine and pulls really well. i have deleted the egr valve and pick p seems better. the problem starts when i attach the intercooler. the car will start to 'drag' when i reach speed of approx 70mph and it doesnt want to go any faster. if it does then it takes ages unless its down hill. its as if i am towing a heavy car behind me. remove the intercooler and everything is fine again.
any ideas?

Otis2 · « **Reply #1 on:** May 21, 2007, 11:04:27 am »

Sounds like you have created a leak somewhere in your intercooler piping, or possibly the intercooler itself leaks under boost pressure.

If you had a boost gauge in the car, I bet you would see a drop in boost pressure @ 70 mph as the boost pressure gets high enough to blow something loose in your intercooler piping.

This kind of thing can be annoying to track down.

One good way to find leaks is to spray soapy water all over the junctions in your piping (and all over the intercooler itself). Then pump pressurized air through the intercooler circuit (eg. use a vaccuum cleaner hose, swapped to the exhaust port on the vaccuum cleaner, and plug it into one end of your intercooler circuit). Then look for any bubbles forming in the soapy water. If you see any bubbles, there's your leak.

nogama3 · « **Reply #2 on:** May 21, 2007, 12:34:40 pm »

car still runs upto 0.8 bar of boost as normal.
gonna have to ake it to a specialist to get to the root of the problem.

jimfoo · « **Reply #3 on:** May 21, 2007, 01:27:26 pm »

But where is your gauge hooked up, before the IC or after?

nogama3 · « **Reply #4 on:** May 21, 2007, 01:51:01 pm »

its on the intake manifold, after the intercooler.
its the black tube in the bottom right hand corner, pics are before i deleted the egr valve.

jtanguay · « **Reply #5 on:** May 21, 2007, 02:05:12 pm »

where do you have your intercooler placed??? how big is it???

what kind of turbo??? K03???

i'd say try upping the boost to around 15 psi and see what happens.

nogama3 · « **Reply #6 on:** May 22, 2007, 02:58:24 am »

intercooler is wing mounted, same as a tdi and i have the k3 turbo mate.
i think i will attach the new stainless steel hoses for the intercooler and see how is runs as before i had a bit of a crazy set up

new set up should look like this:

Black Smokin' Diesel · « **Reply #7 on:** May 22, 2007, 07:33:52 am »

IMHO, your tubing is too big and long for only 0.8bar/11psi so you are losing a lot of efficiency.

Where did you tap the boost gauge? If it's not tapped on the manifold, give it a shot, it'll give you the real boost going into the manifold/engine.

nogama3 · « **Reply #8 on:** May 22, 2007, 10:34:21 am »

the tubing is of a similar length to that of a tdi engine as it follows the same path, so dont think thats too much of an issue. i think it might be due to an air leak/leak from the hoses somewhere. only the attachment of the intercooler pipes will give me an ideas as to what is happening.

jtanguay · « **Reply #9 on:** May 22, 2007, 12:55:31 pm »

try running 15 psi or so... the K03 turbo is really only good for down low boost.

i remember reading about some people disliking the K03 at highway speeds...

johnboy · « **Reply #10 on:** May 22, 2007, 01:47:01 pm »

Hi nogama3, off subject I know, but can you give me some details of what you did to remove the EGR setup on your car, Im thinking of doing the same on my Passat but Im unsure about the electrical side of the removal. Does disconecting the EGR wiring throw up a warning light on the dash? Or do youu just leave it all connected up?
Cheers

nogama3 · « **Reply #11 on:** May 23, 2007, 01:50:23 am »

just got some blanks made by an engineering co using a spare egr valve from the breakers as a guide and cost me £5 GBP. no electrical wires were attached to mine, just a vacuum type 3mm hose which was blanked off by a screw.

car sounds a bit louder now for some reason, especially when i floor it, i just cant stop flooring it !

just got this urge now....

johnboy · « **Reply #12 on:** May 23, 2007, 01:09:42 pm »

So is it worth doing? Can you feel any benefit?

nogama3 · « **Reply #13 on:** May 24, 2007, 02:01:29 am »

car seems to run better with quicker response and a lot less smoke!

worth removing the egr valve i think.