R32gtr Hks T04r Not Enough Boost

[wrxkilla]

Hi all,

I have an R32 GTR with a HKS T04R. Running a HKS 60mm GT wastegate.(venting to atmo) Uses a HKS EVC III boost controller.

At the moment (for track work) 4inch titianium zorst with a muffler no pussy cat.

Also using an Apexi exhaust control valve.

OK I had fiddled lots and lots and lots with boost controller trying to get boost out of her and no matter what I adjusted, still only holding 0.9 bar.

It peaks up at 1.1-1.2 and drops off to 0.9

So for the best way forward is to eliminate the controller from the equation.

Try and bleed off manual boost with wastegate. Have tried every which way combination you could think off to bleed boost of, both vacuum hoses off, one off the other on, the other way round, both getting positive pressure, one getting the other getting, so on and on. So its pretty apparant the physical setup just cant do the deed.

Tried adjusting the wastegate spring tension thing, and no change.

No matter what you try to change the configuration, it would practically ALWAYS run the exact same boost.

So at this point, the wastegate was removed and inspected. It appears to be operating fine. The diaphragm looks in good condition and the spring functions, it opens and closes.(with lots of force lol)

So I think well, must be the wastegate spring, just is worn and cant hold closed. (as if it held closed should build and build and build boost! Lol

So I check HKS website and order the spring configuration for 1.3-1.7 bar – this needs and outer and centre spring. These arrive. Are fitted to the wastegate, manually there is most definitely A LOT more physical force needed to operate as you’d expect.

So back on the car it goes. And whooshka, exact same symptoms.

Been through all the same steps as above again now with new springs in place.

No good.

Only boosts to 0.9bar (peaks to 1.1+)

Now I keep wanting to blame the turbo, but I cant, as its not the turbos fault the wastegate opens up at this point. I just want to be able to keep the sucker closed, to prove it can run the more boost, then we can try control it…

So this has to be a physical problem with the wastegate? Right???

Please any advice or opinions wanted.

Thanks

I have taken a few pics of the wastegate if anyones intrested, not the best but if it helps....

Michael

[paulr33]

way out of left field but youve made sure the evc3 has been reset and is set to external gate mode on the back of the unit ?

[T04GTR]

that doesnt sound like much fun.

so assuming the waste gate is in tiptop shape, and the pressure line is on the bottom of the gate(is your boost controler on external or internal mode)

what exhaust housing is on the turbo and what rpm does it come onto boost?

by that i meen loaded up in third etc. and does it ramp up quickly.

one way you can check the turbo is to remove the wastgate lines altogether

but BE CAREFUL ....

are all the cooler pipes intacted?(masive boost leak)

blow of valves all ok(vac lines on)

let us know so we can dig some more

[wrxkilla]

yep as i say above, i have removed both vacuum hoses from the wastegate, and still only boosts wo this same level...

it should really boost unlimited....bang

(its a 0.96 exch housing - and it boosts up nice and hard - then gate opens at 0.9 and controls boost)

Boost controller is UNLPLUGGED atm.

All tests doing manually. Need to prove it can boost manually before even bothering with the controller. (but yep i did check that too)

any more help is greatly appreciated.

thanks

michael

[T04GTR]

does it have a cat converter? if so remove it. or does it start glowing red just crusing.

[wrxkilla]

no cat, cat is removed.

[T04GTR]

if it only boosts to .9 with no lines on the gate then iether there is a blockage in the exhaust or there is a boost leak.

i dont want to rule out the turbo yet. but as you said with the vac lines of does it leak out past the wastegate still?

[T04GTR]

what airfilters are on it?

does the turbo spin easily by hand?

[T04GTR]

what airfilters are on it?

does the turbo spin easily by hand?

[abflug]

Has the accuracy of the boost gauge been checked.

Just a thought.

[wrxkilla]

boost gauge and the evc (when thats connected) read same reading.

plus i have had it on dyno and it shows same thing.

I havent tried spinning the compressor or anything - will try that....

i did check for shaft play, it was rather minimal.

hks pod filters on it, new foam in atm

[wrxkilla]

OK im thinking of dropping the exhaust to see what effect this has on it....

any more ideas anyone?

really wanting to prove it can be a problem with the wastegate?

thanks

michael

[BHDave]

Intake restriction? It's a long shot.

Try reading the pressure at the compressor outlet and at the inlet manifold and see if there is a significant drop.

Should be easy enough to plug the ebc in at one side and the boost gauge in at the other and have a look.

[wrxkilla]

intake restriction, hrrm never thought of that...

well, i still cant see it being that, that would have nothing to do with the wastegate cracking open and letting the boost out...

but ok will see if i can test that, i doubt it, but with everything i want to rule it out.

Anyone have any insight?

I really dont want to rebuild turbo and find out its not the turbo, or buy new wastegate and find out its not wastegate.

thanks very much

Michael

[BHDave]

You could always bolt a steel plate on instead of the wastegate and see if it has an effect (though you'd want to be pretty careful)

[wrxkilla]

yeah cant do, as the hks GT wastegate uses those clip type conectors, not bolts.

but yeah thats a cracker of an idea, bugger....

mick

[Blitz]

Michael: Pics or ban

Hopefully you get this fixed and start running some proper boost through that turbo!

Nick

[wrxkilla]

Michael: Pics or ban

Hopefully you get this fixed and start running some proper boost through that turbo!

Nick

<{POST_SNAPBACK}>

lol

pics in here:

http://www.gunnamotorsport.com/members/wrxkilla.html

yeah ive spent about a month now trying to fix this, and its getitng frustrating.

ran a 12.3 @112 on 0.9bar.

want low 11s if i can get some bloody boost. im pulling my eyes out.

mick

[RedDrifter]

Check all Your gasket on the manifold, turbo and waste gate.

I had a similar problem when I blew a t3 gasket and not mater what the bc did turbo would only run 13psi max. Boost also came on later and no where near as hard.

Just a thought.

Hope you sort it out.

[wrxkilla]

yeah have checked all gaskets, doesnt seem to be any leaks.

although most guys here are missing the point.

Its running an external wastegate venting to atmosphere.

The wastegate opens and starts screaming at 0.9 bar. and you can hear it! lol

So its defo something with the wastegate i thinks?

just after someone with experience with external gates for any tests i could do, what to check? how to make it stay closed etc???

I have pulled it apart and diaphram looks in fine cond, purchased new springs (that should be keeping it closed until 1.3-.17bar)

bah, im sulking.

mick