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Old 05-17-2006, 01:39 AM   #1
purduephigam
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Default New intercooler and possible boost leak.....please help

just installed a new ebay intercooler (please dont flame). i used their y-pipe and silicone hoses (plus a 3inch silicon coupler). I am one of those freakish people who tightens everything all the time......so i tightened the begezus out of the coupler on the y-pipe and the joints on the y-pipe. everything seems to appear okay, but when i took it on a test run, it sounded like my turbo was a little louder (could've just been me being over perceptive). so there's a possibility of a leak somewhere; but i was still hitting 15 psi.

right now, my only mods are cobb stage II and TBE. with the weather getting a little warmer, should i expect to hit 15 psi, or is there a definate leak? also, i noticed there was no gasget on the bov flange....so i should probably take this pretty seriously regardless, being that this could be an issue in itself (regardless i really made sure the bolts were tight on the bov). any input would be appreciated. thanks
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Old 05-17-2006, 01:44 AM   #2
-Kevlar-
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is it a hard y-pipe? if so check around the i/c connection.....
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Old 05-17-2006, 01:54 AM   #3
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you need all the gaskets
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Old 05-17-2006, 01:56 AM   #4
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Quote:
Originally Posted by MannyMohawk#5
you need all the gaskets

oh dear i didnt even notice he didnt have a bov gasket..... yeah you need that...

Last edited by -Kevlar-; 05-17-2006 at 02:28 AM.
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Old 05-17-2006, 02:25 AM   #5
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Quote:
Originally Posted by MannyMohawk#5
you need all the gaskets
Don't forget the washers too
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Old 05-17-2006, 04:23 PM   #6
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so is it possible that the leak is from the bov flange since i do not have a gasget? i will double check the clamps on the hoses again....
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Old 05-17-2006, 04:28 PM   #7
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You should have a gasket on the BOV, whether or not that is a problem right now.

If you have a wideband you could probably tell better. You'd be running richer than normal under WOT. If you are still hitting target boost and don't notice slower spool up it probably isn't a really bad leak.
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Old 05-17-2006, 04:28 PM   #8
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15 seems a little low for stage 2, but that could be many other things (eg WG arm, bigger intercooler now in need of a protune etc). . . If you tightened it down good it's probably not leaking at the BOV.
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Old 05-17-2006, 05:02 PM   #9
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Target boost is 15.8 psi +/- 0.5psi for stage 2.
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Old 05-18-2006, 01:13 AM   #10
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i attempted to put on the stock-rubberish gasket until the one i ordered comes in, but like you all said, even though it's necessary, it probably isn't the problem. i ran a few spirited runs again today, and hit 11 psi in 1st, and 14/15 in 2nd. now i know something is definately off. my only guess would be the hose connecting to the turbo. i used the stock hose clamp from the coupler because i could not get in there with my hands.....this coupler is tightened all the way, but i think it is still too loose. the only thing i have in mind to remedy this would be to go buy a smaller hose clamp, and clamp the hose at the absolute end of the hose to get a more efficient seal. if this, for some rediculous reason, is not what is causing the leak, i suppose i will have to unclamp everything and remove the intercooler and adjust/tighten the hoses and tighten the cast pipes to the intercooler. any other suggestions or advice for this frustrated newbie?
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Old 05-19-2006, 01:32 AM   #11
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bump....anybody?
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Old 05-19-2006, 02:31 AM   #12
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Just to be on the safe side and pinpoint the area.I would suggest a boost leak test.It could save a lot of time and send you in the direction where the problem is.
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Old 05-19-2006, 02:38 AM   #13
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^^^yes!

for christ sake people, PRESSURE CHECK THE SYSTEM, you're leak(s) will be found easily. Do a search, and find out how to build a pressure tester.


Goodluck, keep us posted,

Ian
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Old 05-20-2006, 01:10 AM   #14
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Default More frustrations....

alright i built a pressure tester, rented a compressed air tank; and thought i found the leak at the silicon coupler attached to the intake manifold. i used a different hose clamp and thought i had made all necessary adjustments. i hooked up my AP so that i might get a more accurate reading of my boost.

i hit 11.5 psi in first and just over 12 in second. obviously i missed the leak somewhere. i ran 20 psi through the turbo inlet and had a difficult time finding the leak. the only thing i think i can do is take off the entire intercooler, re-tighten all bolts and clamps, and reinstall.

if this fails, i am just going to give up and take it to a tuner. any uplifting words from you all?
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Old 05-20-2006, 02:03 AM   #15
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check the y pipe very closely and all of the turbo lines
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Old 05-20-2006, 06:28 PM   #16
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well i did it. i removed the intercooler, and removed all clamps and pipes. i replaced the gaskets and used new clamps (the ones that were supplied were awful). and i replaced the gasket on my bov. i reflashed my ecu at stg 2 93, and just hoped for it to hold.

honestly it was a rough day....i lost my wallet at home depot (fell out of my pocket) and no one had the decency to turn it in (even so i wouldn't have expected any cash), i cut my finger wide open while trimming the silicon coupler, and i had to spend about 30 mins fishing out a bolt from my bov out of my engine bay.....

all said, my brother had to drive my car since i didnt have a license. boost held perfectly at 16 and 16.8. so after all i went through at least i fixed the leak! now i guess i have to wait till monday (after i get a new license) to drive it myself (i'm assuming i won't notice all that much different without a tune). next on the list: grill modification, clay bar/detail, turbo inlet and exhaust mani/upipe, then a protune
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Old 05-20-2006, 07:55 PM   #17
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Quote:
Originally Posted by purduephigam
next on the list: protune
This is where you're gonna feel good gains!

Big TMIC + Full exhaust + custome tune =
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