Forced Induction Custom FI Setup Questions

Turbo won't boost above 7 psi

Old 07-19-2014, 10:21 AM
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Default Turbo won't boost above 7 psi

Hi there, I am from England, been aware of this website from Googling turbo related stuff but never had a reason to register until I ran into problems with my own home built turbo. The guys over on my cars specific website are outta ideas, I was wondering if anyone on here might have ideas.


I have adapted a turbo from another engine to fit on my 1.9 diesel turbo engine instead of the standard turbo and it won't go above about 7psi with a welded wastegate. The turbo was sounding broken before and would make even less peak boost so I pulled it and rebuild it but it still won't go over 7psi. The engine is a very simple mechanically controlled engine, it has no ECU, fuelling is adjusted via a screw on the fuel pump.

So far I have tried:

removed intake completely
welded wastegate
removed wastegate actuator and blocked off actuator takeoff
Checked for boost leaks (would have to be a big boost leak to cause this, I have had boost leaks before on the stock setup and they usually don't effect more than a few psi)
Turned up fuelling to max

Here are a few pictures of the turbo and mani setup:

Adapter plate (partially completed):



Fully completed plate on mani:



Turbo on adapter plate on mani:



Note I've had to block off a couple of extra takeoffs on the comp side of things.

I can only guess something is stalling the turbine shaft at higher rpms (engine and turbo) for some reason. Is it possible for a turbo to be so worn that a rebuild kit will not revive it? I am gonna have to make a decision as to what to do because at the moment this thing is slower than standard but I have spend so much on it that I need to be sure the turbo is junk.
Attached Thumbnails Turbo won't boost above 7 psi-p1010054_zpsf84586f7.jpg   Turbo won't boost above 7 psi-p1010023_zpsb04fba0f.jpg   Turbo won't boost above 7 psi-p1010079_zpscb58d881-1.jpg  
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Old 07-22-2014, 09:48 AM
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Exactly what sort of turbo is this and what did it come off of? It could be the turbine housing is too big for this motor.
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Old 07-22-2014, 11:12 AM
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Good question Matt Cramer, it came off a 2 litre turbo gasoline engine. The turbo in question, a Garrett GT2052S has been tried by other members on the forum (the Peugeot forum) and is said to be quick spooling and a good match for the engine.

However, there appear to be variants of the turbo for both gasoline and diesel engines, as far as I know those who have used this turbo have all used the diesel variant, I bought a gasoline variant by mistake because I didn't know the turbine housing was a different size.

As far as I know if it makes boost to begin with it should make more boost until the engine runs outta revs. But there is soot from the exhaust which in a diesel suggests there too much fuel to air ratio and the fuel is not getting burnt, even though a high fuel level should equate to higher boost, especially with a welded wastegate. It is a real head scratcher, unfortunately I am much the DIY enthusiast and therefore am really quite out of my depth.

Does anyone think that extra solenoid area I have blocked off might be causing problems?
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Old 07-30-2014, 10:11 AM
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The solenoid appears to be a recirculating valve - if it's blocked off in the closed position, it should be OK. If it's stuck open, that could be the problem as well.
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Old 10-05-2014, 02:47 PM
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Yup, didn't block it off properly. I didn't pay enough attention to it, there is a hole down in that channel:



Air went down there and back to the inlet

I just blocked the outside off by plugging the dome shaped thing so the boost was just filling that and then escaping down the hole.

The final solution was a flat plate:

This has had me baffled for months, thanks for the help!
Attached Thumbnails Turbo won't boost above 7 psi-p1010004_zps5fe279d9.jpg   Turbo won't boost above 7 psi-p1010007_zps43fc9b4c.jpg  
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