Club 80-90 Forums

Hulky paid me a visit today and it would appear that the BOV is either opening too soon or possibly the Wastegate is jammed shut.

I would suggest that the BOV is knackered although he's replaced it already, in a brief passenger ride it didn't feel like there was any real assistance from the turbo, seemed to get to the point where it was coming onto boost then suddenly the BOV opens. Didn't seem like a boost leak, the noise is too sudden for that.

Dave.

Well it needs a boost gauge../ .7bar max ish.

davegsm82 wrote:Hulky paid me a visit today and it would appear that the BOV is either opening too soon or possibly the Wastegate is jammed shut.

I would suggest that the BOV is knackered although he's replaced it already, in a brief passenger ride it didn't feel like there was any real assistance from the turbo, seemed to get to the point where it was coming onto boost then suddenly the BOV opens. Didn't seem like a boost leak, the noise is too sudden for that.

Dave.

Thanks for help last night Dave

Just had another look at van thought I would try another cork in BOV cable tied in and test drove and the noise had Gone.....
Then took cork out and turned brass screw on BOV full in and test drive noise has Gone
So is my problem sorted or is there something underlying ?

I wouldn't say it's sorted, more like diagnosed

You should get yourself a boost gauge attached to it and make sure it doesn't get too high a pressure on it. As Dave Friday says, should be about 0.7 Bar which is about 10 PSI. Could still be a seized wastegate and your turbo could be over-boosting.

Dave.

Ok turbo gauge on reading 18 psi second gear up hill full revs with BOV blanked off.
I read a post from Brickwerks that he blankes it off and the JX will handle 18 psi all day long.
So think I will take his advise on this.
Its booked in at Brickwerks for a couple things and am sure it will be sorted once and for all.


Thanks for all the help guys.

18psi without an intercooler???!
Where is the Brickwerks thread that said thats ok?

Quote from vw samba forum


Brickwerks Mon Jan 06, 2014 2:48 pm
I wouldn't worry about boost, with stock fuelling you won't cause any problems.
They will handle 18psi day in day out with no mods.

Engine problems noted above do sound like head gasket failure though.
Usual thing with those is that the tank in the engine bay is half full, then, the tank behind the flap overflows.

Try going up a steep hill with a constant 18psi of boost on a standard engine for a few minutes....

I'd have to agree that 18 psi on full load is dangerous territory even for larger units. Not surprised your BOV is having a hard time.

I would get that turbo out and clean it up, at the very least get the wastegate actuator worked back and forward a good few times, might find its just seized.

Good luck mate, Dave.

Is your van any faster than your inlaws van?

dave friday wrote:Is your van any faster than your inlaws van?

No dave we drove each others van about the same.

Thanks Hulky,I agree with Dave...see if you can unstick/adjust the wastegate.

dave friday wrote:Thanks Hulky,I agree with Dave...see if you can unstick/adjust the wastegate.

I am assuming the turbo needs to come off dave ?
Or is there an easier option ?

You might be able to free the wastegate in situ... though the Schwitzer KKK is harder to work on than the Garrett.
First check the pressure feed pipe to the capsule is intact. You could disconnect the compressor side and try a pump

HarryMann wrote:You might be able to free the wastegate in situ... though the Schwitzer KKK is harder to work on than the Garrett.
First check the pressure feed pipe to the capsule is intact. You could disconnect the compressor side and try a pump

Thanks Harrymann I will have a look to see if I can free it up ?
I am aware this thread is dragging on a bit due to my inexperience