Low Boost And Surging Help Needed

[WYLD333]

Hey guys,
Ive just started having a issue with my patrol its got stock zd30 motor with egr block, pyro and boost gauges.
Anyhow the issue im having is when i give it a bootfull or even put it under a little load it surges alot until i back off and just cruise, it only gets to around 10psi max full throttle and sitting on 100km sits on around 2psi. now ive tried the usual cheaking for leaks ect, clened maf and tps has anyone else got any ideas what my problem could be im starting to think intercooler or turbo on the way out???

[threedogs]

Do you have a DAWES valve fitted???
Sounds a bit like overboosting

[WYLD333]

No i dont have a dawes valve fitted as yet was next on my to do list. How could it be overboosting tho when im getting low boost readings?

[threedogs]

Check for errors, TPS may be faulty, un block EGR again and what happens ;
Whoooa brain not working , got fried my bad, Check IC for leeaks as suggested

[Ben-e-boy]

I would be checking for boost leaks first. especially on the stock intercooler.

[WYLD333]

ok i unblocked the egr, took the engine cover off and went for a drive still no good and at roundabouts was coughing and splatting bad. Could hear some faint hissing sounds so came home and got the mrs to rev the car up in the garage where i found alot of tiny pin holes in the intercooler and alot of bent fins etc leaking boost, so thats where my boost issue lies hope once i put a new cooler on it sorts out the stuttering aswell.
Now bout to head out and block that egr again

[WYLD333]

Fitted a new high flow cooler 2day and put a new fuel filter on while i was going now she's as good as gold

[threedogs]

So was it fuel filter or IC ? We'll never know, lol. good to hear you're up and running again

[WYLD333]

Intercooler was definatley leaking, pin holes everywhere and bent fins, however when i replaced it the car was still surging, so slaped on a new filter and bingo all sweet.
now just need to fit my dawes and im all done for now

[threedogs]

Don't go for big boost,doesn't work that way, 15 psi seems to work well on most, instead of stretching spring to get more boost when the time comes slip s/s washers in as spring is a bugger to un stretch if you go too far. Then go get it Dynoed

[WYLD333]

washers is good idea mate, i wont have the valve for a few days and then will fit it. wont go over 15psi atm am only making around 12 psi hence the order of the valve

[threedogs]

It will go into overboost anyway. Doing needle valve too??
Helped mine heaps

[WYLD333]

was going to do just the dawes first and see what comes of that, would you recommend doing the needle also?

[threedogs]

Mine kept spooling up too quick, put needle valve under bonnet as a set and forget.
no regrets doing it only cheap mod as well, see how you go first,

[WYLD333]

Cheers thanks for the input bud

[BillsGU]

Mine kept spooling up too quick, put needle valve under bonnet as a set and forget.
no regrets doing it only cheap mod as well, see how you go first,

What happens when it spools up too quick? Is it bad for the engine? How can you tell?

[WYLD333]

If it spools up to quick ull b getting higher boost levels

[BillsGU]

If it spools up to quick ull b getting higher boost levels

No you won't. The dawes valve makes that impossible.

[WYLD333]

No you won't. The dawes valve makes that impossible.

Yeah good point lol

[threedogs]

Now you'll need a bigger exhaust to increase boost as well.

[WYLD333]

Now you'll need a bigger exhaust to increase boost as well.

Yeah maybe u could ask the fun police (the mrs) 4 me n let me know how u go

[threedogs]

Simple my friend, simple. Your MOF already knows your 4x4 playing up, right, right.
Now to fix this you need to increase the OD of the exhaust throw in some big words here
like wheelbarrow, Read a few threads where increasing has not only fixed other ppls 4x4 problems but also added some much needed power
as well. Don't even get me started on diff locks lets just focus on exhaust for now. Goodluck
Doesn't hurt if you can tear up at the drop of a hat either

[WYLD333]

Lmao maybe if it was my everyday drive i mite b able 2 get away with it, but i have a wrk car n she drives the 4by most the time