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No spool before 5k rpm


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#1 thyssenkrupp

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Posted 20 April 2015 - 03:40 AM

Morning folx,

Got an issue with the turbo set up.
My car is equipped with a completely stock TC06-11A (49168-1412) turbocharger unit.

The problem is that it barely builds any boost, and in order for it to hit paximum psi (0.7 bar) I have to be pretty close to the redline.

From previous experience this could be due to a faulty waste gate actuator.

Other than that, the car is running fine.

1985 Starion Flatty 2.0 turbo (180 hp) 4g63





#2 importwarrior

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Posted 20 April 2015 - 05:10 AM

wastegate arm is possibly unattached.
vac lines leaking
vac line hooked up wrong to waste gate
Vac Line popped off of wastegate or OVC Pipe ( over valve cover pipe )

IS Wastegate a 1 port or 3 port???

B-71 87 TSI ~ RIP

Black 87 Starion ~ Mess SOLD!!!

Proud New 89 slightly Rusted Fiji Owner !!!




#3 thyssenkrupp

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Posted 20 April 2015 - 06:05 AM

Hmm, what bothers me is that everything worked splendedly about a week ago.
All the vac lines are new, and as far as I can see its a 1 port.

But I will double check all that you mentioned Importwarrior...

#4 creakyjoints

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Posted 20 April 2015 - 06:57 AM

check and make sure that the nut on the compressor wheel has not come loose
the dude in the honda said, i thought you said your car was slow, my response was.. well you said yours was fast so i guess we both lied.. haha

#5 importwarrior

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Posted 20 April 2015 - 07:31 AM

check the turbo turbine flange is tight and manifold to head nuts are tight no exhaust leaks.
wastegate flapper arm not enough tension when put on the flapper.

B-71 87 TSI ~ RIP

Black 87 Starion ~ Mess SOLD!!!

Proud New 89 slightly Rusted Fiji Owner !!!




#6 Fuze

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Posted 20 April 2015 - 11:29 AM

Possibly there's a potato stuck in your muffler?

I kid, I kid...

Sounds like a wastegate problem, as if it's opening early but you don't hear about that happening much except like Importwarrior said, if the arm came off the flapper..

If not that, the bearings in your turbo may be toast. I'd take the inlet hose off and make sure you can spin the shaft, and that the wheel isn't contacting the housing. If it won't spin, or the blades touch, and the center nut is tight, it's time for a new turbo. If either of these are the case, also check/replace the oil feed line.

Edited by Fuze, 20 April 2015 - 11:31 AM.

Insta = @battlemagnet

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#7 thyssenkrupp

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Posted 20 April 2015 - 02:04 PM

Here is what I found out today.

Took the heat shield off and got to the turbine, checked movement in both flapper and wastegate actuator.
Both seemed fine, WG actuator holds pressure and vacuum (tested) the flapper "sounds" allright, not like it has been deattached from the arm inside the housing. Changed the old vac.line to the OVC pipe and took it for a spin. Seems a tad better, so full boost at around 4k now. Still not the way it was a week ago.

I have an uneasy feeling about this deal, especially now that she's going up for sale.

I notice a little bit of oil on the intake side of the turbocharger, but that could be from the crank case vent as well....hummmmm.

Will check for movement in the turbine shaft tomorrow after work.

Am I forgetting something else here?

Thanks for all the input so far!!!

Edited by thyssenkrupp, 20 April 2015 - 02:07 PM.


#8 thyssenkrupp

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Posted 21 April 2015 - 01:01 AM

Woke up this morning, drove the car to work, seemed to be back to normal.
Conclusion, something sticks... Does the EGR valve play a role? Should I unbolt and clean in? Would that help any? All the vac hoses are now new as well, couldnt get any sleep last night so I went and worked on the Starion.

20150418 163906

Edited by thyssenkrupp, 21 April 2015 - 01:06 AM.


#9 importwarrior

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Posted 21 April 2015 - 05:00 AM

to me what seems to happen is that the wastegate gets removed and or disconnected from the flapper and when it is put back on its not tight enough. or not enough tension. when connecting the wastegate arm to the flapper it takes a lot of pressure and pliers to get it attached.

B-71 87 TSI ~ RIP

Black 87 Starion ~ Mess SOLD!!!

Proud New 89 slightly Rusted Fiji Owner !!!




#10 thyssenkrupp

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Posted 21 April 2015 - 05:33 AM

So what you are saying is that I might need a new WG actiator, since mine is getting weak?

#11 Fuze

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Posted 21 April 2015 - 07:09 AM

I think what he's saying is that you should adjust the arm on the WG until it's short enough that you need a pair of pliers to get it on the WG actuator, so it's held closed tightly. If it's not closed tight, boost will leak past the WG port and steal performance from the turbine.

Insta = @battlemagnet

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#12 DieHARDmitsu.

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Posted 21 April 2015 - 11:25 AM

Wastegate flapper arm could be stuck or jammed partially. This would limit movement and leave it slightly open. Inspect the flapper/arm, move it by hand. It should move freely from full open to close.
Boost leak, bad turbo or leaking exhaust manifold/gasket can also cause similar issues.
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#13 thyssenkrupp

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Posted 21 April 2015 - 11:31 AM

Just got back inside, there is no exhaust leaks, the flapper moves freely (took the cover w. downpipe off to look inside. using a little mirror) no play in the turbine shaft.
Fuze and Importwarrior, pliers are indeed needed to get the wg. actuator arm on the flapper. The actuator is a factory part, and was adjusted to 0.8 bar boost, which I have no intentions to exceed. However the WG actuator on my 155 Q4 turbo is way harder to pull out and connect to the flapper.

So in conclusion, the wg actuator must be weak/bad. Will one from TC05 fit TC06-11A turbo?

#14 Fuze

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Posted 23 April 2015 - 07:15 AM

What are those TC05 turbos from? All US spec models come with TD05 turbos.

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#15 thyssenkrupp

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Posted 28 April 2015 - 02:36 AM

This should explain it ;) here is the variet of turbochargers fitted to the Starion... Mine is red colored txt... 180hp (...or at least was)

1) TC06-11A (8 cm2 turbine housing) non intercooled 4G63 2.0 litre SOHC (Australia, JDM, Europe)
2) TC06-11A (8 cm2 turbine housing) intercooled 4G63 2.0 litre SOHC (Australia, JDM, Europe)
3) TC05-12A (6cm2 turbine housing) non intercooled JDM 4G63 2.0 litre SOHC (JDM)
4) TC05-12A (6cm2 turbine housing) intercooled JDM 4G63 2.0 litre SOHC (Australia, JDM)
5) TD05-12A (8cm2 turbine housing) non intercooled 4G54 2.6 litre (USA, JDM, Europe)
6) TD05-12A (8cm2 turbine housing) intercooled 4G54 2.6 litre (USA, JDM, Europe)




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