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Thread: NOT for the faint hearted!

  1. #1
    Regular Member nutron's Avatar
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    Vehicle : Vauxhall

    Trim : very

    Engine : Z19DTH

    Year : Nosey

    Lightbulb NOT for the faint hearted!

    I've been abusing my car again, in ways that would make most take a big step back!

    Having established that I could keep the waste gate close all the time and produce over 30psi, I was left pondering a way to control the boost to stop the ECU fitting.

    It came to me while I was in one of those half consious moment, while I was deep in though trying to get to sleep.

    I rigged up the same pieces as before but in the order shown below. I'll start by explaining how the standard setup works for those who don't know.

    The turbo waste gate diverts exhaust gasses around the turbo turbine, in order to reduce it's speed and thus reduce the boost pressure it produces. The waste gate on the 1.9CDTI is normally open which mean the gasses bypass the turbine and the turbo doesn't spin up. This must be for safety, if it goes into limp home mode for example. There is a vacuum line from the engine to the waste gate that the ECU controls, so that it can close/open the waste gate to control boost. Still there?

    Right, now what I did was to grab a DC vacuum pump, a 'T' piece, a mechanical bleed valve (boost controller from Halfords) and some pipe. I then connected the vacuum pump to the waste gate through the 'T' piece to hold the gate closed all the time (all the gass flowing over the turbine for max pressure). The third leg of the 'T' piece was connected to the normal vacuum line via a variable restrictor (my modified boost controller). The normal vacuum line varries the vacuum as I said, so without the restrictor the system would act pretty much as normal with the vaccum being released by the ECU controlled line. Because of the restrictor though, my vacuum pump holds the waste gate closed more than the ECU would and as such I get a crude adjustment to the level while leaving the ECU more or less in control.

    The result is that boost now peaks at upto 28psi on over boost (as apposed to 24psi) and holds at 24-26psi (as apposed to 22psi).

    Don't know what the bhp/lbft result is as yet but hope to get some figures next weekend or the weekend after. Doesn't suffer from increased lag and I've abused it in sixth upto ... well more than one should and it didn't complain.

  2. #2
    Regular Member nutron's Avatar
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    Vehicle : Vauxhall

    Trim : very

    Engine : Z19DTH

    Year : Nosey

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    Sorry, forgot to add this

  3. #3
    Regular Member Caterman's Avatar
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    Vehicle : Signum

    Trim : Elite

    Engine : 3.2 V6

    Year : 05

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    Got to admire you for having the b@lls to do something like this with a new car.

    It will be interesting to see if it causes you any problems and what the increases are

  4. #4
    Regular Member Ian's Avatar
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    very nice work!! I take it that the 1.9CDTi doesnt have an electronic boost control solenoid then - or is that installed on the OE vacuum line?

  5. #5
    Full Member Big Sig's Avatar
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    Whats the next step? Could you get a remap with a different actuator to hold the boost at a higher psi and not make the ecu go tits up?
    Now I need a turbo to keep up!

  6. #6
    Regular Member Higgins's Avatar
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    Sounds interesting. Id make a right mess ot it though!

  7. #7
    Regular Member nutron's Avatar
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    I'm not sure how it controls it as yet, haven't bodged around enough yet. I just know that it produces varying levels of vacuum down to nothing basically.

    I'm going to be trying another custom map with increased boost and fueling pressures, so I wanted to see if it would run correctly and if I could do it myself.

    If I was going to leave it like this forever, I would look at removing the waste gate and reducing the strength of the sping to see if that would increase the boost or if the ECU would compensate as I suspect it might.

    I can get the waste gate to stay closed all the time as I said and the psi goes off the scale of my 30psi boost gauge. Problem is, the fuel/air mix is all wrong then and the ecu just won't have any of it... Not sure how much the seals would take either.

    Definatly don't want to be running lean as that would lead to over heating and the potential of the engine seizing!

  8. #8
    Regular Member Gsi3.2's Avatar
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    the other problem is how much more boost than when the wastegate opens can the rings and headgasket handle??...

    Top respect again for trying something different....

  9. #9
    Regular Member nutron's Avatar
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    Vehicle : Vauxhall

    Trim : very

    Engine : Z19DTH

    Year : Nosey

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    Just ragged it again... all working okay but it gets hot quick! It was upto 92 deg after burning around for 20 minutes!

  10. #10
    Regular Member Hideous's Avatar
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    Vehicle : Insignia

    Trim : SRi Nav

    Engine : CDTI158

    Year : 2012

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    You're crazy! My first thought when hearing about increased boost was uh oh.. head gasket too (real expensive if it goes wrong I'm told), but I guess there's only one way to find out what it can handle haha... for those brave enough that is!

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