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Boost problems after T5 swap

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

S60UT
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Year and Model: 2001 S60 T5
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S60UT

Boost problems after T5 swap

Post by S60UT » Sun Jul 28, 2019 11:32 am

I purchased a 2000 S70 GLT auto with a blown engine. I swapped in a low mileage T5 engine from an 01 S60 T5. After the swap i was getting fuel trim CEL and intermittent boost problems. SteveO just recently tuned my ECU to play nice with the larger turbo and injectors. Car has more torque and shift points seem higher. And no more CEL for fuel trims !! Sometimes the car boosts and sometimes nothing. I installed a boost gauge and when it does boost im only boosting to 5psi. Steve tuned the ECU to boost to 15. Following parts have been replaced and troubleshooting thus far...

New silicone hoses from turbo to TCV
New Pierburg TCV
New PCV system
Did cigar smoke test and no major leaks to intercooler piping
Bought a hand held vac pump and diaphrams for the CBV and wastegate held at 5 "
Wastegate adjusted to fully closed position. This turbo dosent have the thimble adjustment that i thought all P2's came with ?
ETM passed the sweep test in VIDA
Car idles perfectly and accelerates with no hesitation
Any help here would be greatly appreciated. Im so close to having this car running properly.


01 S60 T5 Manual
00 S70 GLT
00 S70 GLT SE T5 Swap

jimmy57
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Re: Boost problems after T5 swap

Post by jimmy57 » Sun Jul 28, 2019 12:12 pm

The waste gate actuator should have preload when slipped on pin on lever for waste gate. The pressure is something like 25 kPa/3.6 psi before the rod will slip onto pin on lever with no loading. Does the elver move freely when rod is not installed on lever?



S60UT
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Re: Boost problems after T5 swap

Post by S60UT » Sun Jul 28, 2019 12:33 pm

yep, it moves freely without any tension at all. You are referring to the lever that opens and closes inside the turbo and not the rod attached to the waste gate spring and diaphram, correct ?


01 S60 T5 Manual
00 S70 GLT
00 S70 GLT SE T5 Swap

S60UT
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S60UT

Re: Boost problems after T5 swap

Post by S60UT » Sun Jul 28, 2019 12:52 pm

https://photos.app.goo.gl/ERB5e9jw36W7v7eW9

yep there is no tension whatsover on the lever. Hopefully this link to video works


01 S60 T5 Manual
00 S70 GLT
00 S70 GLT SE T5 Swap

jimmy57
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Re: Boost problems after T5 swap

Post by jimmy57 » Sun Jul 28, 2019 2:03 pm

Yep, that is not good. The first bit of boost made will open the wastegate. Just for testing loosens the 10mm nut and screw the end 2.5 turns and install and go drive. I think you'll have an answer.



S60UT
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Re: Boost problems after T5 swap

Post by S60UT » Sun Jul 28, 2019 2:14 pm

Thanks for the response, if i turn it 2.5 times (towards passenger side) wont that be opening up the lever to dump boost instantly ? I was also thinking of disconnecting the waste gate hose and clamping the lever in the closed position and doing some half throttle runs in the neighboorhod to see if boost improves and or is consistent ? Your thoughts ?


01 S60 T5 Manual
00 S70 GLT
00 S70 GLT SE T5 Swap

jimmy57
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Re: Boost problems after T5 swap

Post by jimmy57 » Sun Jul 28, 2019 2:36 pm

Shorten the rod 2.5 turns (towards driver side). That will make you pull it against spring for it to reach pin on lever. That preloads the waste gate closed and the diaphragm will have to have some boost pressure before it begins to move



jimmy57
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Re: Boost problems after T5 swap

Post by jimmy57 » Sun Jul 28, 2019 2:39 pm

I advise against driving with no waste gate working. The boost will build then explosively spike and that can bend connecting rods. I know this personally from the hose breaking on one of my vehicles, a 98 T5. Later rods are better.



S60UT
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Re: Boost problems after T5 swap

Post by S60UT » Sun Jul 28, 2019 6:50 pm

I cant believe i was thinking of this adjustment in reverse. I adjusted per your advice and noticed a little change. I adjusted some more and as you can see im just about maxed out of adjustment. Im now pulling about 6.5 psi. and not over boosting because im sure the car would go into limp mode to protect itself. With the fact that im about maxed out on wastegate and not overboosting, it may be time for a new turbo $$$ replacement ?? Also, would you recommend tapping the boost gauge into the tube from TCV to compressor wheel ? Im currently tapped into the tube that connects to the nipple on the drivers side of the intake manifold. Thanks again !!

Image


01 S60 T5 Manual
00 S70 GLT
00 S70 GLT SE T5 Swap

scot850
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Re: Boost problems after T5 swap

Post by scot850 » Sun Jul 28, 2019 7:01 pm

The standard TCU is only designed to run up to 12 psi. If you are boosting to 15 psi you will likely have issues with boost. If you go for a better TCU that can cope with the extra boost, if you decide on the IPD version, I always advise the installer to only screw the middle (front) leg of the 3 legs in by 3-4 turns MAX. Yes it will feel loose, but any more than that and it will crush the little mesh screen preventing the valve opening or making it random.

Good luck,

Neil.


2000 V70 R - still being an endless PITA
2006 XC70
2003 Toyota 4Runner V8 Limited
2015 Kia Sportage EX-L
1993 850 GLT -Sold
1998 V70 XC - Sold
1997 Volvo 850 SE NA - Went to niece in California - Sold
2000 V70 SE NA - New project and test bed - Sold

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