T5R boost question / help please

[ITSv40]

Just an observation and I could be talking out my a*se - I generally do. As new intercoolers are non-existent could you buy a secondhand one and take it to a radiator repair specialist for pressure testing before you rip your car to pieces. At least you would be able to present a known good intercooler to the garage before incurring labour costs and finding out afterwards that the replacement is no good. There is a cost to all this but it may limit the overall cost and hassle.

[Pupbelly]

It is a very good point and I have a pressure/vacuum kit that I could do a test using. There’s a local radiator repair centre to my work but when I asked they don’t do intercooler work. Bugga!

I’m doing my research at the moment and I’ll have to just crack on and make a decision because I really want to get the car used!

[Jod T5]

Originally Posted by Pupbelly

What level of boost should be displayed on the stock boost gauge under full boost?

The needle on my car goes about 1/4 into the white section, and there doesn't feel to be the surge of power I would expect.

I would be prepared to put a heavy wager you have a vacuum leak from the elbow (left hand side) of your inlet manifold.


FWIW my '96 T5 with a MBC and RICA 304 went off the white scale with no issues. It was similar with a Don Norchi (Kalmar Union) map too.



Does your car judder on WOT?



Cheers,


Jod

[Pupbelly]

Originally Posted by Jod T5

I would be prepared to put a heavy wager you have a vacuum leak from the elbow (left hand side) of your inlet manifold.


FWIW my '96 T5 with a MBC and RICA 304 went off the white scale with no issues. It was similar with a Don Norchi (Kalmar Union) map too.



Does your car judder on WOT?



Cheers,


Jod

Hi Jod, no judder on WOT at all, it just revs as normal but won’t go beyond an indicated 2-3psi.

The rubber elbow that seems to feature on a lot of photos looks to have been replaced by what looks like braided hose which I then assume connects to the white small bore plastic pipe that runs behind the inlet or maybe the PCV piping down by the turbo inlet??
Is there an easy way to get at that elbow (that’s not there) to make sure it’s airtight?

My post about the intercooler is as a result or a smoke test being done on mine which created smoke whisps from the top assuming a crack or something. I’m now wondering if the smoke was actually coming from that vent hole at the bottom so there’s actually no issue either the intercooler?? I only saw a video clip the garage took of the whisps as they had a camera looking at the top of the intercooler. I’d rather not pay to have the front pulled apart if the intercooler is not the issue. I’ve already committed to replacing the radiator not that it needs it but thought it made sense whilst the rad pack was being removed.

Any thoughts?

[Jod T5]

Hey, the white pipe is part of the PCV system. if you are not getting the boost as indicated on you in car screen, I would deffo look at this area.


Even tho it was over thirty years ago that I first fiddled with the 20V saab and 20v Volvo system i would be sure your lack of boost or boost leak would be from this area. The fact the elbow has been replaced does not prove the white hose is complete, as far as it should be down to the PCV valve, or that your PCV valve is working as it should. The white brittle hose often breaks in line or where it bends into the PCV valve elbow due to heat of the engine damage. Trust me, seen it 100 times.
Unfortunately over the last few years experts such as I, BB54 and Chris Rogers have drifted to new pastures. My mentor Chris Rogers has forgotten more than Wayne and I ever knew. Brian (shadetek) is what is left of the old school.


I wish you luck with your car but always remember to eliminate the obvious first. ****ing Volvo's.


All the best,




Jod

[Pupbelly]

Ok so update. Replacement intercooler pressure tested and all ok. Replacement intercooler fitted. No change! Nothing. WTF??

What is going on? The garage did a cylinder test and all 5 are circa 150psi so is that about normal?

Everything has now been swapped. Turbo, inlet pipe work, vacuum lines, turbo control valve, throttle position sensor, swapped the turbo recirculation valve, all turbo pipe work with DO88, and replacement intercooler.

Air getting in, turbo spooling, exhaust out (which is flowing fine).

Doing a smoke test under pressure highlights no pipe work leaking, the only quirk is it will smoke from the dipstick and oil filler when the system is pumping smoke into the engine. So what’s the issue here?

Would anything on the PCV create a near zero boost? It’s as though something is not connected or mis routed but everything appears to be fine but clearly isn’t. No oil burning, no blue smoke, no white smoke, no weird noises.

I’m at the end of my tether here. Anyone??

[sdg1970]

Originally Posted by Pupbelly

Ok so update. Replacement intercooler pressure tested and all ok. Replacement intercooler fitted. No change! Nothing. WTF??

What is going on? The garage did a cylinder test and all 5 are circa 150psi so is that about normal?

Everything has now been swapped. Turbo, inlet pipe work, vacuum lines, turbo control valve, throttle position sensor, swapped the turbo recirculation valve, all turbo pipe work with DO88, and replacement intercooler.

Air getting in, turbo spooling, exhaust out (which is flowing fine).

Doing a smoke test under pressure highlights no pipe work leaking, the only quirk is it will smoke from the dipstick and oil filler when the system is pumping smoke into the engine. So what’s the issue here?

Would anything on the PCV create a near zero boost? It’s as though something is not connected or mis routed but everything appears to be fine but clearly isn’t. No oil burning, no blue smoke, no white smoke, no weird noises.

I’m at the end of my tether here. Anyone??

I'm speechless tbh, but on we go!

RE PCV: When I replaced the crank sensor on mine a couple of years back, I accidentally broke the lower PCV pipe that runs very close to it coming off the turbo inlet. Rather than be overly concerned and prior to getting a replacement pipe, I just masked it up for a fortnight and it made absolutely NO DIFFERENCE AT ALL to boost/vac (I have a vac/boost gauge too).

My thoughts would now look to the ECU and either it's gone bad (very rare but known) or somebody has put a non-turbo version in. You'll need to cross reference your ECU numbers with known turbo/non turbo variant numbers. Isn't there an ECU list on this forum somewhere??

[Pupbelly]

Originally Posted by sdg1970

I'm speechless tbh, but on we go!

RE PCV: When I replaced the crank sensor on mine a couple of years back, I accidentally broke the lower PCV pipe that runs very close to it coming off the turbo inlet. Rather than be overly concerned and prior to getting a replacement pipe, I just masked it up for a fortnight and it made absolutely NO DIFFERENCE AT ALL to boost/vac (I have a vac/boost gauge too).

My thoughts would now look to the ECU and either it's gone bad (very rare but known) or somebody has put a non-turbo version in. You'll need to cross reference your ECU numbers with known turbo/non turbo variant numbers. Isn't there an ECU list on this forum somewhere??

I am baffled but surely even with an iffy ECU it would offer some boost wouldn’t it?
The guy at the garage said you can squeeze the intercooler pipe and rev the engine and it should swell as it revs but it doesn’t but gives a slight swell if you rev it and snap the throttle shut. So where’s the intake charge going? It can’t be the turbo because it’s been swapped. The pipe work to the turbo has been changed for DO88 stuff. I’m baffled!
Curiously I do have another ECU which is meant to be remapped but I was holding off plugging it in until I got the car running as I want it.

[sdg1970]

At this stage of the game, where much, much more has been replaced and eliminated, than what's left, then I'd stick that remapped ECU on and eliminate something else. If that doesn't work then I'd bite the bullet and send it to a Volvo specialist.

[Luxobarge]

You don't have a partially blocked exhaust do you? Any way you can run it for a short time without the cat connected?