i have built a 2.0 zetec turbo, using decomp plate, inlet adapter to use frs turbo inlet and ecu, and zetec flange welded onto erst t3 manifold with t3 turbo, front mount intercooler and universall pipe kit off ebay, but it will only boost to like 1-2psi and just feels like a diesel to drive, thats even with the pipe removed off the actuator, intercooler has no leaks and nor does the piping had it pressure tested, any ideas why its not boosting? also wont tick over and runs really rough and miss fires under half throttle, do you think it could have a air leek between the adapter plates on the inlet manifold and thats where its loosing all the boost and thats whats making it run rough?

 

One thing I have done in the past is to remove a inlet pipe and run it like a N/A and then rev it with your hand over the intercooler outlet and see what pressure you get there , if you have pressure then it is getting that far , it could be a leak and that is what is causing the misfire , sometimes difficult to find , another trick is to start it in a sealed state and spray some brake cleaner towards your suspected leak area , only a quick squirt though , it will get sucked in and will burn like petrol and it will rev , so be careful how much you use .

 

fghfghf

 

ok will get tome break cleaner tomorrow and give that a try, took the pipe off the intercoler and when revved loads off air is coming out so its getting that far, and its only a t3 turbo so will be fine on the 2litre

 

ghjghjgh

 

Surely on a boosted engine there is no vacum so if you spray brake cleaner where you suspect a leak it will be blown out by the leaking boost rather than get sucked in?

 

What preload do you have on the actuator?

 

There will be vacuum when throttle is shut from the throttle plate to the valves , boost only comes in at higher revs .

 

Well took the inlet manifold adapter plates off today, put a bit of instant gasket on the gaskets ticks over a lot better now and is boosting to around 5-6psi a lot quicker than before but that is still with the actuator pipe off and it wound all the way in, so do you think I need a new actuator? Will replace the inlet gaskets aswell, no leeks on the intercooler pressured them up to 25 psi and not one leak so all good there

 

And also feels really laggy gets to about 4000 rpm before starting to make boost

 

how was you controlling the boost

 

I have no boost controller only the pipe that goes to the pipe that goes from the actuator to turbo no amal valve

 

what management are you using ?

 

Fiesta rs turbo ofac ecu, beigh injectors and 195 chip

 

try winding the actuator back and puting a bleed vave in the pipe from actuator to turbo. and is the adaptor plate true and staight. get a stright edge on it. how was the maifold welded inlet and exhaust.

 

Okay will give that a try, want to get a new actuator though becaue if I blow air into it it leaks out instead off mooving the rod out so guess its no good haha, have not checked the inlet adapters but will be getting new gaskets for them because they are leaking, and I bought the exhaust manifold already welded

 

well check the exhaust manifold is stright as sometimes the welding warps them. and same with inlet.

 

Okay will do mate thanks, just want it running well enough to take it to dyno to get it set up properly o

 

As I asked earlier - about preload...

It sounds like your actuator is indeed fucked. If the actuator isn't preloaded correctly and holding the internal wastegate penny shut it will behave exactly as you've described.

 

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