om603 intercooler boost drop
om603 intercooler boost drop
04-21-2013, 02:04 PM
#1
Still cant go past 1bar. Its like the magical limit... the holset wont go over 1 bar, and the stock kkk wont go over 1bar.....
My only conclusion is that it is because of the intercooler.... Maybe a pressure drop or something... :-)
![[Image: 5u1c0o.jpg]](http://oi34.tinypic.com/5u1c0o.jpg)
![[Image: 16huv01.jpg]](http://oi34.tinypic.com/16huv01.jpg)
Any suggestions??
This post was last modified: 04-21-2013, 02:08 PM by Ducos.
Hi. I've had some problems with getting boost on my HX35. So i changed back to the stock turbo, and removed the wastegate plumbing so it would give maximum boost.
Still cant go past 1bar. Its like the magical limit... the holset wont go over 1 bar, and the stock kkk wont go over 1bar.....
My only conclusion is that it is because of the intercooler.... Maybe a pressure drop or something... :-)
Any suggestions??
04-21-2013, 03:41 PM
#3
the holset wont boost without more fuel and your stock turbo will open at whatever spring pressure the wastegate is set at.
fit some heavy external springs on your wastegate or clamp the rod and do a quick test and see if boost increases, but watch you dont blow that standard turbo as it wont like so much boost.
This post was last modified: 04-21-2013, 03:44 PM by mantahead.
is your injector pump standard?
the holset wont boost without more fuel and your stock turbo will open at whatever spring pressure the wastegate is set at.
fit some heavy external springs on your wastegate or clamp the rod and do a quick test and see if boost increases, but watch you dont blow that standard turbo as it wont like so much boost.
04-21-2013, 03:42 PM
#4
(04-21-2013, 02:56 PM)Mark_M Where are you measuring boost from, manifold or turbo? If your measuring at the turbo it can't be your intercooler. If your at the manifold then try the turbo end and see what you get. How sure are you that your gauge is correct?
And what kind of exhaust are you running?
EDH_Performance
04-21-2013, 03:42 PM #4(04-21-2013, 02:56 PM)Mark_M Where are you measuring boost from, manifold or turbo? If your measuring at the turbo it can't be your intercooler. If your at the manifold then try the turbo end and see what you get. How sure are you that your gauge is correct?
And what kind of exhaust are you running?
04-22-2013, 11:21 AM
#5
From intake manifold.
Full 3inch exhaust with 2 small straight through mufflers.
Not runnig lines to the original KKK wastegate, just plugged the hole in the turbo., (im from norway/europe)
Pretty sure i dont have any boost leaks... spent some hours yesterday going over everything....
Thanks
(04-22-2013, 11:21 AM)Ducos Stock pump.
From intake manifold.
Full 3inch exhaust with 2 small straight through mufflers.
Not runnig lines to the original KKK wastegate, just plugged the hole in the turbo., (im from norway/europe)
Pretty sure i dont have any boost leaks... spent some hours yesterday going over everything....
Can i tighten the orginal wastegate screw to increase pressure to the wastegate "pole" ?
Thanks
(04-21-2013, 03:41 PM)mantahead is your injector pump standard?
the holset wont boost without more fuel and your stock turbo will open at whatever spring pressure the wastegate is set at.
fit some heavy external springs on your wastegate or clamp the rod and do a quick test and see if boost increases, but watch you dont blow that standard turbo as it wont like so much boost.
I'd love to do that. but its the KKK turbo with built in wastegate, most stupid turbo I've ever seen.... haha :-))
(04-21-2013, 02:56 PM)Mark_M Where are you measuring boost from, manifold or turbo? If your measuring at the turbo it can't be your intercooler. If your at the manifold then try the turbo end and see what you get. How sure are you that your gauge is correct?
Pretty sure.. because at about 3000rpm the engine wont produce any more power. Just slowing easing up the speed.... feels like a.. 200d with 3tonns in the trunk.. but with the holset, it looked like .9 - 1bar with air was enough.. I did get 1.6-1.7bars when the engine was in my 190D.. No logic at all!
This post was last modified: 04-22-2013, 11:37 AM by Ducos.
Stock pump.
From intake manifold.
Full 3inch exhaust with 2 small straight through mufflers.
Not runnig lines to the original KKK wastegate, just plugged the hole in the turbo., (im from norway/europe)
Pretty sure i dont have any boost leaks... spent some hours yesterday going over everything....
Thanks
(04-22-2013, 11:21 AM)Ducos Stock pump.
From intake manifold.
Full 3inch exhaust with 2 small straight through mufflers.
Not runnig lines to the original KKK wastegate, just plugged the hole in the turbo., (im from norway/europe)
Pretty sure i dont have any boost leaks... spent some hours yesterday going over everything....
Can i tighten the orginal wastegate screw to increase pressure to the wastegate "pole" ?
Thanks
(04-21-2013, 03:41 PM)mantahead is your injector pump standard?
the holset wont boost without more fuel and your stock turbo will open at whatever spring pressure the wastegate is set at.
fit some heavy external springs on your wastegate or clamp the rod and do a quick test and see if boost increases, but watch you dont blow that standard turbo as it wont like so much boost.
I'd love to do that. but its the KKK turbo with built in wastegate, most stupid turbo I've ever seen.... haha :-))
(04-21-2013, 02:56 PM)Mark_M Where are you measuring boost from, manifold or turbo? If your measuring at the turbo it can't be your intercooler. If your at the manifold then try the turbo end and see what you get. How sure are you that your gauge is correct?
Pretty sure.. because at about 3000rpm the engine wont produce any more power. Just slowing easing up the speed.... feels like a.. 200d with 3tonns in the trunk.. but with the holset, it looked like .9 - 1bar with air was enough.. I did get 1.6-1.7bars when the engine was in my 190D.. No logic at all!
04-22-2013, 02:14 PM
#6
But does an om603 have any type of Overboost protection on it?
'82 300D -3" straight pipe, ALDA deleted, 3in1 glowshift gauge, HX30, egr-less manifold, A/W intercooler
'14 Ram 6.7l cummins -G56 handshaker, wishing it was deleted
I don't know, just throwing ideas out there.
But does an om603 have any type of Overboost protection on it?
'82 300D -3" straight pipe, ALDA deleted, 3in1 glowshift gauge, HX30, egr-less manifold, A/W intercooler
'14 Ram 6.7l cummins -G56 handshaker, wishing it was deleted
04-22-2013, 02:53 PM
#7
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
04-22-2013, 02:53 PM #7Is the ALDA hooked up?
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
04-23-2013, 03:07 AM
#8
W201 2.5 turbo, restored, stock, aut. -89
W220 320cdi
Mazda RX-7 FD man. -92
The alda is long gone, the engine is 100% mechanical.. pump is maxed out so far it almoast wont return to idle. Got off the phone with a mate yesterday, he made a boost tester.. Will try today after work :-))
W201 2.5 turbo, restored, stock, aut. -89
W220 320cdi
Mazda RX-7 FD man. -92
04-23-2013, 01:07 PM
#9
(04-23-2013, 03:07 AM)Ducos The alda is long gone, the engine is 100% mechanical.. pump is maxed out so far it almoast wont return to idle. Got off the phone with a mate yesterday, he made a boost tester.. Will try today after work :-))
Found a boost leak: now the engine is tight!
Adjusted the wastegate out maximum een though its not connected!
Still wont go past 1bar! And car is reaaaally slow after 3000.
Why wont my turbo go any higher than 1bar???
It kills me :-((
W201 2.5 turbo, restored, stock, aut. -89
W220 320cdi
Mazda RX-7 FD man. -92
(04-23-2013, 03:07 AM)Ducos The alda is long gone, the engine is 100% mechanical.. pump is maxed out so far it almoast wont return to idle. Got off the phone with a mate yesterday, he made a boost tester.. Will try today after work :-))
Found a boost leak: now the engine is tight!
Adjusted the wastegate out maximum een though its not connected!
Still wont go past 1bar! And car is reaaaally slow after 3000.
Why wont my turbo go any higher than 1bar???
It kills me :-((
W201 2.5 turbo, restored, stock, aut. -89
W220 320cdi
Mazda RX-7 FD man. -92
04-23-2013, 02:24 PM
#10
If it was still bolted on but not hooked up it would cause this
is the pump timing correct?
This post was last modified: 04-23-2013, 02:26 PM by willbhere4u.
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
04-23-2013, 02:24 PM #10When you say the ALDA is removed you mean its off the pump all together right!
If it was still bolted on but not hooked up it would cause this
is the pump timing correct?
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
04-23-2013, 03:37 PM
#11
I think my manifold/turbo gasket is toast... Can see signs of black smoke comming out of there... My dad had time to help me search today!
Will mount the holset back on and buy a new gasket + grind both so they are perfectly clean :-))
W201 2.5 turbo, restored, stock, aut. -89
W220 320cdi
Mazda RX-7 FD man. -92
Yes its gone:-)
I think my manifold/turbo gasket is toast... Can see signs of black smoke comming out of there... My dad had time to help me search today!
Will mount the holset back on and buy a new gasket + grind both so they are perfectly clean :-))
W201 2.5 turbo, restored, stock, aut. -89
W220 320cdi
Mazda RX-7 FD man. -92
04-23-2013, 03:53 PM
#12
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
04-23-2013, 03:53 PM #12When I got my 87 300sdl om603 the last cylinder on the rear of the intake manifold was cracked by the flange and was blowing oily boost on the back of the engine it was a real mess. I replaced it and its runs much better now
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
04-23-2013, 05:22 PM
#13
(04-23-2013, 03:53 PM)willbhere4u When I got my 87 300sdl om603 the last cylinder on the rear of the intake manifold was cracked by the flange and was blowing oily boost on the back of the engine it was a real mess. I replaced it and its runs much better now
Thats a good advice, I borrowed a pressure tester witch i connected to the turbo intake, and applied 0.3bar pressure. and the pressure was almoast perfectly stable, so the problem has to be at the exhaust end i think.... do you agree?
W201 2.5 turbo, restored, stock, aut. -89
W220 320cdi
Mazda RX-7 FD man. -92
(04-23-2013, 03:53 PM)willbhere4u When I got my 87 300sdl om603 the last cylinder on the rear of the intake manifold was cracked by the flange and was blowing oily boost on the back of the engine it was a real mess. I replaced it and its runs much better now
Thats a good advice, I borrowed a pressure tester witch i connected to the turbo intake, and applied 0.3bar pressure. and the pressure was almoast perfectly stable, so the problem has to be at the exhaust end i think.... do you agree?
W201 2.5 turbo, restored, stock, aut. -89
W220 320cdi
Mazda RX-7 FD man. -92
04-24-2013, 10:00 AM
#14
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
04-24-2013, 10:00 AM #14Yea if its leaking exhaust before the turbo
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
04-24-2013, 03:38 PM
#15
runs really well now. but wont get more than 1 bar on the holset, think its lack of diesel
W201 2.5 turbo, restored, stock, aut. -89
W220 320cdi
Mazda RX-7 FD man. -92
Mounted the holset with the new gasket and did 240 sand paper on the manifold and turbo just to be sure :-)
runs really well now. but wont get more than 1 bar on the holset, think its lack of diesel
W201 2.5 turbo, restored, stock, aut. -89
W220 320cdi
Mazda RX-7 FD man. -92
04-24-2013, 05:13 PM
#16
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
04-24-2013, 05:13 PM #16Put a clamp on the waste gate rod and try it again. I had a t3 Garrett that would never go over 7psi I even disconnected the waste gate hose and block it off still would not go over 7psi the exhaust back pressure was opening the waste gate internally because of a week spring.
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
04-24-2013, 05:40 PM
#17
3 turns 1.2 bar pressure after intercooler at inlet, and the intercooler is in no way optimized, wierd turns, and looks more like something found on a scrapyard than a serious build.
3.5 turn = 1.5bar pressure
and from what i know, the om602 turbo is significantly smaller than the om603?
either way. good luck!
This post was last modified: 04-24-2013, 05:41 PM by swampmonkey.
---------------------------------
daily driver
w115 240d 72hp 3.07 rearend
w123 om602 turbo 200whp 7.5mm pump fivespeed 3.07 rearend
+ a few more.
mbturbo.com
swampmonkey
04-24-2013, 05:40 PM #17om602 with org turbo, ALDA. Pump turned out/up 3 turns, high idle, had to mix with idlestabilizer to get it down,
3 turns 1.2 bar pressure after intercooler at inlet, and the intercooler is in no way optimized, wierd turns, and looks more like something found on a scrapyard than a serious build.
3.5 turn = 1.5bar pressure
and from what i know, the om602 turbo is significantly smaller than the om603?
either way. good luck!
---------------------------------
daily driver
w115 240d 72hp 3.07 rearend
w123 om602 turbo 200whp 7.5mm pump fivespeed 3.07 rearend
+ a few more.
mbturbo.com
04-25-2013, 01:24 AM
#18
(04-24-2013, 05:13 PM)willbhere4u Put a clamp on the waste gate rod and try it again. I had a t3 Garrett that would never go over 7psi I even disconnected the waste gate hose and block it off still would not go over 7psi the exhaust back pressure was opening the waste gate internally because of a week spring.
Thanks for the tip. But the wastegate is totaly disabled. Did å hoseclamp on the lever and to a screw, spotwelded to the rod so it dont fall off:-)
When the car changes gear it goes down to 0.7bars before it rises again.. Straaaange!!
Thanks!
(04-24-2013, 05:40 PM)swampmonkey om602 with org turbo, ALDA. Pump turned out/up 3 turns, high idle, had to mix with idlestabilizer to get it down,
3 turns 1.2 bar pressure after intercooler at inlet, and the intercooler is in no way optimized, wierd turns, and looks more like something found on a scrapyard than a serious build.
3.5 turn = 1.5bar pressure
and from what i know, the om602 turbo is significantly smaller than the om603?
either way. good luck!
Post some pictures!
I recall seeing a graph that te pump decreases dieselfuel to the engine as the rpms are getting past. 4xxx rpm... If i turn up the rpms. Will this graph be moved forward?
Hard to explain so early in the morning..
This post was last modified: 04-25-2013, 02:17 AM by Ducos.
W201 2.5 turbo, restored, stock, aut. -89
W220 320cdi
Mazda RX-7 FD man. -92
(04-24-2013, 05:13 PM)willbhere4u Put a clamp on the waste gate rod and try it again. I had a t3 Garrett that would never go over 7psi I even disconnected the waste gate hose and block it off still would not go over 7psi the exhaust back pressure was opening the waste gate internally because of a week spring.
Thanks for the tip. But the wastegate is totaly disabled. Did å hoseclamp on the lever and to a screw, spotwelded to the rod so it dont fall off:-)
When the car changes gear it goes down to 0.7bars before it rises again.. Straaaange!!
Thanks!
(04-24-2013, 05:40 PM)swampmonkey om602 with org turbo, ALDA. Pump turned out/up 3 turns, high idle, had to mix with idlestabilizer to get it down,
3 turns 1.2 bar pressure after intercooler at inlet, and the intercooler is in no way optimized, wierd turns, and looks more like something found on a scrapyard than a serious build.
3.5 turn = 1.5bar pressure
and from what i know, the om602 turbo is significantly smaller than the om603?
either way. good luck!
Post some pictures!
I recall seeing a graph that te pump decreases dieselfuel to the engine as the rpms are getting past. 4xxx rpm... If i turn up the rpms. Will this graph be moved forward?
Hard to explain so early in the morning..
W201 2.5 turbo, restored, stock, aut. -89
W220 320cdi
Mazda RX-7 FD man. -92
05-04-2013, 04:54 AM
#19
(04-25-2013, 01:24 AM)Ducos Post some pictures!
no picture, but clip.
got a leak on one of the prechambers, (2nd) and the entire interior is torn apart for the rustpreventionspray in doors and weelding of floor.
stock engine, stock turbo, 2.5" exhaust, dialed up pump 2.75 turns or something, 3.07 rearend, the pressure meater is connected over the alda pipe, so at the very end before the inlet.
http://www.youtube.com/watch?feature=pla...hXJpnu2PMw#!
This post was last modified: 05-04-2013, 05:01 AM by swampmonkey.
---------------------------------
daily driver
w115 240d 72hp 3.07 rearend
w123 om602 turbo 200whp 7.5mm pump fivespeed 3.07 rearend
+ a few more.
mbturbo.com
swampmonkey
05-04-2013, 04:54 AM #19(04-25-2013, 01:24 AM)Ducos Post some pictures!
no picture, but clip.
got a leak on one of the prechambers, (2nd) and the entire interior is torn apart for the rustpreventionspray in doors and weelding of floor.
stock engine, stock turbo, 2.5" exhaust, dialed up pump 2.75 turns or something, 3.07 rearend, the pressure meater is connected over the alda pipe, so at the very end before the inlet.
http://www.youtube.com/watch?feature=pla...hXJpnu2PMw#!
---------------------------------
daily driver
w115 240d 72hp 3.07 rearend
w123 om602 turbo 200whp 7.5mm pump fivespeed 3.07 rearend
+ a few more.
mbturbo.com
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