I have a 1987 300TDT wagon. I just swapped a used engine into it that I think was from a 1986 300SD. The car now runs, but I'm only getting around 1 PSI of boost out of the turbo. The turbo shaft turns freely, and there is no noticeable play. It sure sounds like it is spinning pretty fast when I gas it. I have checked the EGR valve, and it is closed with no vacuum applied.

I have tested the boost at 4k-5k rpm with no load, and also driving full throttle up my steep driveway (car isn't registered yet, so I can't take it out on the road). I only got 1 to maybe 2psi on the gauge I hooked up to a hose I ran through the window.

I haven't tried to debug the ALDA yet, since it seemed to me that if the engine wasn't making any boost to speak of it wouldn't get activated anyway.

The new engine has the KKK-K24 turbo with air recirculation valve on it (my old one has what I think is the Garret with the external large wastegate control diaphragm). Unfortunately, that turbo is completely siezed, so I can't just swap it in.

I'm thinking that the wastegate could be stuck open. It also might be that the air recirculation valve is leaking. I haven't got all the vacuum lines sorted out yet, so I didn't hook anything up to the air recirculation valve.

My questions are:

1. Can you take off the wastegate control valve on the KKK-K24 without taking the turbo out? This looks like it just might be possible to do, although it won't be easy.

2. It looks like the air recirculation valve is opened by vacuum, so it shouldn't reduce boost to have it not hooked up. Is this correct?

3. If I have to take the turbo out, is there some sort of walk through on how to do it? It looks pretty hard to do, and I sure wish I had checked the wastegate before I put the engine in..

Thanks for any info..

Max Behensky

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1981 Datsun King Cab Diesel pickup
1982 240D 4 speed manual
1987 300TD wagon
1991 300D 2.5 turbo