88bhp 2.5 tdi t4

[nwk]

hi all i,ve fitted an intercooler to my van hoping to make it better on hills but it has made no difference at all.also have blanked off the egr valve on the advise of a guy that works for a vw dealer. the inside of the valve and the inlet manifold was quite oily and sooty. is this normal and how do you remove the inlet manifold?

[lund-dean]

blowbly via the EGR system causes the oil you see in the inlet. But this shouldnt be excessive, but then again depends on how long ago it was cleaned. But yes it is normal, most modified vehicles will use a catch can to prevent this problem.

where did you mount you intercooler? have you noticed an increase in turbo lag? you could get a vacuum gauge and then adjust the acutator on the waste gate to give youself some more boost. Although i am not sure what a safe boost level is.

[nwk]

hi thanks for your reply. the intercooler is fitted over the engine. its from a 102 bhp model. do i extend or shorten the acutator arm to give it more boost? the turbo doesn,t seem to do much so maybe that needs adjusting anyway.

[lund-dean]

hi, stock intercooler is ok, but is not very efficient at cooling air while sitting on top of the engine, but when your moving its ok. the 102bhp also have a vent in the bonnet to help with cooling.

you need to shorten the actuator, but this is a cow boy way of doing it, just make sure the peak boost isnt too high, as this method leads to boost spikes.

your turbo should be doing a lot. take the pipes of it and get some one to rev it and you can feel how much pressure is being created. check your pipes for any leaks too, and make sure the exhaust gaskets are not leaking.

ttyl

[nwk]

hi there. i fitted the vent when i fitted the intercooler to help with the air flow. i took the pipe off that comes out of the intercooler and got somone to rev it. wasn,t much pressure so i adjusted the nut on the acutator by 2 turns and it made a lot of difference and goes better than it ever did before. so i,ll get the boost pressure checked to make sure its what it should be. thanks for your help