Turbo over boosting/wastegate not opening

Post by **charlyW** » 06 May 2010, 08:03

All of a sudden my T-5s turbocharger is either over boosting, no where near as badly as the first drive home, or the wastegate has stuck.

Boost needle is now sitting at 3/4 @ 50-80mph before that moves with the gearchange
Car slightly hessitates at 60-80mph slightly but definatly there

Will check the system once the engine cools down

Post by **jblackburn** » 06 May 2010, 08:22

VACUUM LINES!!!

Post by **charlyW** » 06 May 2010, 08:30

That's what I'm thinking........or hoping..... I did notice was the chaps assistant said my BCS lines were on the wrong way and swapped them over not sure why it didnt show up on the dyno run after remapping maybe it did but wasn't picked up, I've called the company who have said if it continues get the car back to them and they will recheck the map

Forgot to add it's just had a remap on the ECU now runs 285bhp and 375NmTorque.

Post by **jblackburn** » 06 May 2010, 08:36

Here's the 3 lines from the TCV to the turbo:

What remap did you use?

Post by **charlyW** » 06 May 2010, 08:48

the remap is a RICA 304. Once the engine has cooled I'll have a look

Post by **charlyW** » 06 May 2010, 10:13

Update on the problem checked all vacuum hoses none split/moved all correctly fitted so I moved onto the wastegate to see if it was stuck it wasnt but took 6 turns at a pressure of 4psi to get the pin to drop on the rod cap once that was adjusted took the car for a test run completely different boost ok now

Post by **charlyW** » 06 May 2010, 13:42

The problem is still there at the top of the boost. How do I test the BCS? and or is there another test I can peform before ordering a new BCS

Post by **boosted5cyl** » 06 May 2010, 14:17

Not 100% sure what you mean by BCS. If you are referring to the TCV (Turbo Control Valve, n volvo terms if you will) then this will help:

http://minimopar.knizefamily.net/solenoids.html

Post by **charlyW** » 06 May 2010, 14:20

The electronic unit on the airbox with three hoses Yellow/Red/Blue is what I'm calling the Boost control solenoid you might call it a TCV then there is the other electronic unit on the fresh air hose I call a PTC no idea what you call it.

Post by **jblackburn** » 06 May 2010, 14:27

Any luck tracing the vacuum hoses to see what goes where? I suspect that they're just hooked up incorrectly at the ports on the valve itself, usually that's the reason for overboosting and fuel cut.

Usually as the TCV starts to fail, you just loose boost pressure as the valve doesn't like to open up anymore.