I have been troubleshooting my car for the last week or so, as I had talked about previously. I had some time recently to take a closer look at the engine, thanks to school being done for the quarter and getting a week break before I started work.
I started off by taking a closer look at the list of things I had suspected to be the problem:
- A hole or tear in an air hose.
- Compressor bypass valve (CBV) failure.
- Turbo control valve (TCV), AKA boost control solenoid (BCS) failure.
- Significant restriction in the exhaust system.
In the previous post, I ruled out number four by detaching the exhaust after the turbine outlet temporarily.
Since then, I have checked for vacuum leaks and made sure the TCV functions properly by checking manifold pressure throughout the RPM range. The pressure gauge indicated good idle vacuum at around 19 mmHg, which is approximately where it should be. Though this basically rules out vacuum leaks, a cursory glance at the vacuum lines showed that if any are leaking, the cracks are small enough to not be seen at idle.
The turbo was generating around 10 psig of boost at wide open throttle (WOT) by 2300 rpm, and held up until around 5500rpm, when I shifted into third gear. Because of this behavior, I believe that the TCV is operating properly in that the wastegate is held to a position that will allow just enough air around the turbine wheel to generate the 10 psig of pressure the ECU calls for.
This leaves the CBV or something else that I didn’t immediately think of. Without explaining my suspicions to him, I took my dad out for a drive to see if he heard anything strange, as he has better hearing than I do. After after accelerating hard in second gear from around 20 to 45mph, he pointed out a wooshing noise that started soon after I got on the gas. I listened more carefully for the noise he was describing, and it sounded exactly like the CBV on Charles’ WRX after we removed the Snorkus.
So from this, I am certain the CBV diaphragm is leaking a lot, which means that a lot of compressed air is going back to the compressor inlet. The compressor must then spin faster to make the same amount of boost at a higher mass flow rate. This means two things, both pretty bad. First is an obvious one; The faster the turbine/compressor wheels spin, the more wear there is on the turbo overall. The second is not quite as obvious. Since the turbo is now doing more work to move that extra air through the CBV, the wastegate is not open quite as far as before, which results in more backpressure on the engine. This reduces power and increases exhaust gas temperatures a bunch, especially in the top end when the turbo has to do the most work.
What’s next? I need to get ahold of a CBV diaphragm for a Mitsubishi TD04HL-16T turbo to replace the current one, and see what happens from there. Just for the sake of being thorough, I should replace the vacuum lines too. Age and heat does wonders for rubber, and I’m sure that even if the idle vacuum is good, there are tiny leaks here and there, which bothers me to think about. As with all other works in progress, I’ll update you guys on anything that happens.
June 3rd, 2008 |