Well gang...

Mopar1973Man is down... I had a air system failure yesterday about Council, ID climbing the grade and passing a RV and heard. BOOM! Psssst.... As I let off the throttle the noise stopped. Get back into the throttle and boost might climb to 5-8 PSI, pyro going like a rocket, lots of black smoke and the noise returns... I stopped in New Meadows, ID for a moment to look and can't see the leak... so I stopped at the hardware store to pickup the stuff to build a boost tester. So I'll be fixing 2 leaks now A/C and boost...

I have to get one too. Got a leak somewhere. Thought I found one of my boots chafed thru. Turns out there was not a whole there, yet. Must be somewhere else, gonna have to pump it up.

I have to get one too. Got a leak somewhere. Thought I found one of my boots chafed thru. Turns out there was not a whole there, yet. Must be somewhere else, gonna have to pump it up.

Multiple ways to do it - just make sure it fits your turbo inlet compressor and TIGHT.

http://i95.photobucket.com/albums/l125/pdltrk/Truck August 2010/P1000164640x480640x480.jpg

http://i848.photobucket.com/albums/ab47/oudive/4inchboostleaktesterconnected.jpg

http://i1004.photobucket.com/albums/af163/idahocountryboy/Trucks/tester.jpg

What size threads are on a male air hose fitting? 4" plumbers tube is to big, 3" is tight but it will work.

What size threads are on a male air hose fitting? 4" plumbers tube is to big, 3" is tight but it will work.

think i just used a drill into the pvc ... and stepped up until it was real tight. USed a lot of pvc glue to help hold the air - no leaks even with that cowboy aussie hack. but if you in lowes/home depot/ace they can help match the threadsize

A 4" Fernco like in the last photo is what I was thinking of. You can get them at Lowes or Home Depot. I can only find a 4 to 3 inch one, but the premise is still the same. A 4" fernco will fit the turbo inlet nicely and then you just need to get what it takes to get down to the inlet size for an air fitting. I just was not sure how much pressure the fernco would handle. Apparently enough. They are in the plumbing department.

I got a 4" fernco but it was to big, 3&1/2" would be perfect. Maybe the hose clamp will make the 4" fit but its dark outside now so I will mess with it more tomorrow.

The inlet on my 02 is just under 4.5". I have a hx 35 are ours that differant?

--- Update to the previous post...

A 3" Fernco will fit 3.5", the od of a 3" pipe.

I got a small piece of 3" pipe, cap and 3" fernco and it took a screwdriver and I nearly broke my finger nail half way off getting them together.

--- Update to the previous post...

Ok, I have a huge leak inbetween the intake plenum and head I guess. I just went and got new gaskets for under and over the grid heater and the leak is still there. Its on the valve cover side so I cant pinpoint the exact spot but its got to be from under the plenum. Is there a gasket under there?

I got a small piece of 3" pipe, cap and 3" fernco and it took a screwdriver and I nearly broke my finger nail half way off getting them together.

--- Update to the previous post...

Ok, I have a huge leak inbetween the intake plenum and head I guess. I just went and got new gaskets for under and over the grid heater and the leak is still there. Its on the valve cover side so I cant pinpoint the exact spot but its got to be from under the plenum. Is there a gasket under there?

Yes

http://www.crazycarlsturbos.com/Intake-Gasket-Kit-Intake-Gasket-Kit.htm

Take apps/intake off and grid heater .......

Undo injectors Line #1

Slide it back.

Put gasket and plenum back on by sliding it back in - its kinda hard - but doable.

Ok, the guy at cummins couldnt find it when I went an hr ago but I just taked to another parts guy and he found it. I dont have to pull the lines off or anything? Probably the five 8mm bolts that hold the lines to the plenum?

Ok, the guy at cummins couldnt find it when I went an hr ago but I just taked to another parts guy and he found it. I dont have to pull the lines off or anything? Probably the five 8mm bolts that hold the lines to the plenum?

Only #1 you can get it off without taking all lines off. IF you dont mind taking lines off - you will find it easier - its tight sliding it in and out which makes getting gasket in place hard work. Yeah once apps and intake and heater off then the bolts for plenum itself (a couple) ........ thats it

I dont want to mess with the lines so I will do like you said. Called cummins and they have one so I guess im going back.

--- Update to the previous post...

Got it out without pulling any lines, just loosened the clamps on the lines. Do I need to put a little silicone on the bolts when I put it back together?

I dont want to mess with the lines so I will do like you said. Called cummins and they have one so I guess im going back.

--- Update to the previous post...

Got it out without pulling any lines, just loosened the clamps on the lines. Do I need to put a little silicone on the bolts when I put it back together?

I just used thread lock blue. But yes you can get boost leak through the bolts so something like a gasket/silcone will help also.

I found putting the gasket back in together with the plenum a real PITA. Let us know if you find/have any useful tips on that after your done

Mine went in really easy, just loosening all the blue clamps.

--- Update to the previous post...

Got my leaks fixed.

Spool better ?

Didnt really get a chance to test it yet, will get on the interstate tomorrow on my way to the diesel drags. It should because it was a massive leak. Seems that egt's are a little higher but that seems backwards to me.

Mine went in really easy, just loosening all the blue clamps.

--- Update to the previous post...

Got my leaks fixed.

When you first tested booster, was there a loud shrieking sound? Is this normal? Is this the wastegate actuator?

I had the air compressore set to 10-15psi and the leak was so bad I couldnt get a reading on my boost gauge in the cab but I never heard any from the waste gate. My tester was leaking a little so I really couldnt tell if the it was leaking though.

When you test the intake for boost leaks ther will be no pressure on the wate gate. It is on the exhaust side and should get no pressure.