Boost leak at 10psi

[Country_GU]

That's just it I can recreate it with the car parked, it's gonna be hard to find shirt of taking it to a dyno and pinpoint it as it spools

[threedogs]

I'd fashion up an EGR blanking plate out of a jam tin lid or similar just to make sure its not the egr pipe that's split.
This is only only to find the noise. but you keep saying its boost related.
what condition is intercooler in??

[Country_GU]

Near brand new, only done 90,000 if that, still perfectly clean inside, bit of dust on the outside and a couple of dents from stones

[mudski]

Hi Country_Gu. I have my money on the egr pipe has warped where it mounts to the manifold. You will need to remove the entire EGR pipe. Get some wet and dry onto a piece of glass and sand the facing flat. Once done, block the EGR and be done with it....

Cheers.

Mark.

[Country_GU]

Righto guys I shall have a look tomorrow, thanks for the help, I have a crd egr pipe I "procured" from a job at work, except its off a crd zd30, they have completely different egr systems don't they?

[happygu]

Righto guys I shall have a look tomorrow, thanks for the help, I have a crd egr pipe I "procured" from a job at work, except its off a crd zd30, they have completely different egr systems don't they?

Yep,

They connect totally in different spots and are different from what I have heard - DI is at the rear, and CRD at the front and is watercooled.

[Country_GU]

Anyone want a free crd egr pipe then? Got an exhaust manifold too..... Ill block it and see what happens, also is the vacuum tank that sits beside the intercooler needed? Any advantages/disadvantages in having it?

[mudski]

You talking about the vacuum canister? Beer can sized thingo' with the vac line going in and out? If so, you can remove it if you want. Most of them get brittle and break where the hose goes in, or out. If you are keeping the engine cover on you still need the bracket that the canister mounts in though.

Cheers.

Mark.

[Country_GU]

Yeah that's it, so no disadvantage without it? Plus with the t bolt clamps I can't put the cover on anymore :/ probably cool the intercooler a little better without a piece of plastic blocking it

[mudski]

Yeah I use Constant torque clamps and the cover wont fit. So I dont have it on now. With T-bolt clamps you really should use spring loaded ones too. These will never come loose. Normal t-bolt clamps are really designed for boost pressures, albeit not much they are really made for intake hoses...

Spring loaded t-bolt clamp.
CLAMPS-AUTOMOTIVE_CLAMPS-SPRING_LOADED_T_BOLT_CLAMPS.jpg

Constant torque clamp.
CLAMPS-AUTOMOTIVE_CLAMPS-CONSTANT_TORQUE_CLAMPS.jpg