Engine Cut Out

[Mike Trout]

Thanks for all your efforts guys. I'm going to devote time this weekend to make sure that the wastegate is not seized, and then make a decision whether to take on the porting project. It cetainly sound like this is the answer, and once done we can consider the chip you are recommending without worrying about overboost anymore.

You are a bunch of real nice helpful enthusiasts, and I will keep you informed of progress - or indeed cry out loud for HELP!!! if needed.

Cheers for now.

MIKE

[lotuska]

Mike,

If you are considering the wastegate port my advice would be not to even try and undo the nuts holding the wastegate manifold to the turbo. They may look perfectly rust free (mine did) but 2 of my snapped the studs off and the others stripped the threads of the studs. So I had to replace all of the studs. I think (someone will correct me if wrong) that these are the types of nuts that can not be unscrewed. I'd split or cut the nut off.

[Enright]

Mike,

Before diving headlong in, can you measure the exhaust diameter and post the result?
If you can reach in under the rear driver's side wheelarch and get a pair of calipers round the exhaust, we may be able to verify the nature of your problem.

I'm thinking that if it's 2" then it's most likely a sticky wastegate actuator.
But if it's 2 1/4" (or more) then it's more likely to be boost creep, which will require porting of the wastegate.

Like Lotuska says, if you decide to port the wastegate, do whatever you can to avoid having to take the turbo off the exhaust manifold.
You're best off getting the PAS pump and dipstick out of the way, and then removing all of the exhaust manifold studs into the engine (once you've snapped all the heatshield bolts off)!

[Mike Trout]

Righty Ho chaps.

Will take a look at all this tomorrow (Saturday) and let you know what size the exhaust is. Thanks for the advice. If I decide to go ahead and remove the turbo, I'll take your advice and remove the whole exhaust manifold/turbo complete.

Watch this space and wait for the screams!!

MIKE

[Mike Trout]

Well guys. Having found that the waste gate was free, and having measured the exhaust system by the rear wheel as suggested (turns out to be 62mm or 2.5ins) I dived in with all guns blazing. The turbo and manifold is off, and I've ported the waste gate to 21mm as recommended.
Altogether v pleased with today's efforts.

I need a new exhaust gasket but that's about all. Just hope I can remember where everything goes when I put it back together. Can't wait to try it out.

Assuming all is well (which it had better be after this bloody lot) who do I contact about one of these chip installations you lovely chaps were talking about?

MIKE

[GeoffSmith]

who do I contact about one of these chip installations you lovely chaps were talking about?

Our very own ESM (Alan) at elanchips.com.

[Mike Trout]

Well guys, what can I say. Thank you so much for the help and advice. The whole thing is a resounding success. It goes like stink, and no sign of cutting out. Revs to the red line with gusto. Even managed the whole thing without stripping a single bolt.

Fiddly job though. Definately not for the inexperienced mechanic.

Take care you guys, and thanks again.

Cheers
MIKE