New to this, zd30 boosting all over the shop

[Theoblackhammer]

Ok so i just brought a 2006 zd30tddi manual 355000ks stock as a rock bar from bull bar and snorkel.
I have fitted boost and egt gauges but having trouble with boost or so I think so.
Here's what's happing,
First and second gear no problems with boost nice and smooth and holds around 15/18 psi
Third gear will go 10 psi then drop to 3 psi then will stay there for a bit then it will go to 15 psi and then I feel a jerk then goes straight back down to 3 or even 0 psi
Pretty much the same with forth an fifth
Is this normal for a vnt turbo
Help would be much appreciated

[nipagu7]

so a 2006 model is not a crd . i reckon your probably hitting limp mode . if you have a dawse and needle valve , adjust the boost to 15 psi , above this you will hit limp mode . use the needle valve to control the rate that the turbo spools up . if you don't have dawse and needle valves my guess is that either you have a 3 inch pipe , or a egt blanking plate or both and they are causing the erratic boost issue , in which case you need a dawes and needle valves to control the boost . but first check all hoses and connections and intercooler for leaks / splits .

[Theoblackhammer]

so a 2006 model is not a crd . i reckon your probably hitting limp mode . if you have a dawse and needle valve , adjust the boost to 15 psi , above this you will hit limp mode . use the needle valve to control the rate that the turbo spools up . if you don't have dawse and needle valves my guess is that either you have a 3 inch pipe , or a egt blanking plate or both and they are causing the erratic boost issue , in which case you need a dawes and needle valves to control the boost . but first check all hoses and connections and intercooler for leaks / splits .

Thanks for reply
Yup 2006 model with direct injection
Has stock exshaust
Not sure on egr blanking plate how do i tell ?
Replaced all vacuum lines
Checked actuator holds vacuum and does not leak
Intercooler has been pressure tested to 20 psi was good no leaks
No codes coming on
The vains are free (easy to move up and down )
I also have clean maf/map sensors
Changed boost control solenoid (tested and works fine)
And if I put my foot down to over take or hill climb it will still pick up and go but I'll have no boost (in between 0-3psi
I have no idea what it could be

[nipagu7]

when the boost drops ( say under load , going up a hill ) if you lift your foot off the pedal momentairly then accelerate again , does the boost come up before dropping again . it sounds like this is what is happening . this is hitting limp mode . i am not sure but , i don't think a code is registered when this happens . i would suggest fitting a dawse and needle valve . search this site for info on these valves and also the blanking plates there is lots of pictures , diagrams and location information here that can help you understand and fit and adjust these items if you wish to do so . they are one of ,if not the most common mods that people make to zd motors . study up on these as when they are properly set up you can use them to fine tune them to have the car running the way you want . they are part of the nads system and most would suggest you apply this to your car .

[Theoblackhammer]

when the boost drops ( say under load , going up a hill ) if you lift your foot off the pedal momentairly then accelerate again , does the boost come up before dropping again . it sounds like this is what is happening . this is hitting limp mode . i am not sure but , i don't think a code is registered when this happens . i would suggest fitting a dawse and needle valve . search this site for info on these valves and also the blanking plates there is lots of pictures , diagrams and location information here that can help you understand and fit and adjust these items if you wish to do so . they are one of ,if not the most common mods that people make to zd motors . study up on these as when they are properly set up you can use them to fine tune them to have the car running the way you want . they are part of the nads system and most would suggest you apply this to your car .

Hey mate thanks for the input I'll look up the dawes and needle valve
Also I was having a fiddle this morning and found that the little grub screw thingy that stop the vain arm was all the way out and not stopping it could this be a factor ?

[nipagu7]

possibley . the boost actuator is very sensitive .i have never played with mine , but others that have , have run into difficulty getting it adjusted right . most just leave it as is from factory. the grub screw has a locknut on it , if it is loose or has vibrated off and the grubscrew has moved it maybe the problem . there are paint markings on it that may help get it back to the right position

[Theoblackhammer]

possibley . the boost actuator is very sensitive .i have never played with mine , but others that have , have run into difficulty getting it adjusted right . most just leave it as is from factory. the grub screw has a locknut on it , if it is loose or has vibrated off and the grubscrew has moved it maybe the problem . there are paint markings on it that may help get it back to the right position

Ok thanks I want it to be just stock not trying to mod it or anything
But the grub screw dosnt have a locking nut on it also do you think you could post a pic for a reference for me I know it's not gunna be the same but just give me a ball part figure to start thanks

[threedogs]

Can I ask which intercooler you have?
If its stock and oily its leaking they all do.
best to buy a fully tigged after market one
Brunswick diesel sell great ones, while your at it you
might want to block the egr valve as well.
a highly recommended mod

[Theoblackhammer]

Can I ask which intercooler you have?
If its stock and oily its leaking they all do.
best to buy a fully tigged after market one
Brunswick diesel sell great ones, while your at it you
might want to block the egr valve as well.
a highly recommended mod

Hey mate stock intercooler as far as I know but it's tig welded and has been pressure tested and all ok

[threedogs]

Hey mate stock intercooler as far as I know but it's tig welded and has been pressure tested and all ok

good if they look oily they are leaking even if just a small oily patch