Excellent! Discovery of the Offender.
 

'Best penetrating oil product: Kroil (Or the spray product ) Aero Kroil

Penetrating-Lubricating Oils

800-311-3374

I was going to say no need to remove the turbo but I see the T25 wastegate is part of the turbine housing. The T3 in the 603 has a separate wastegate housing.

If you can do it, remove the flap from the shaft. There's no pressing need to since the flap stays open by default. If you remove the actuator but not the flap, wire the flap open.

Sixto
MB-less

2nd on Kroil !

Okay so I got it freed up with heat... and a grinder... and a hammer. Had to cut off the arm and pound it out and sand down the shafty. it was STUCK. Im also stuck on waiting for parts so heres some pics of whjat ive done.

Gunk that I scraped out of the intake manifold, wtf.

http://i560.photobucket.com/albums/s...pshpo6jzv7.jpg

Don't know what this port is for, but it was DEFINETLTY clogged

http://i560.photobucket.com/albums/s...ps221dmfvw.jpg

Egr probably wasn't working very well...

http://i560.photobucket.com/albums/s...psf7toad7s.jpg

Look at all that space!

http://i560.photobucket.com/albums/s...psf7toad7s.jpg

Making the EGT adapter (For testing purposes)

http://i560.photobucket.com/albums/s...psms6mvgzt.jpg


Washer and bung

http://i560.photobucket.com/albums/s...psfkqtbrxz.jpg

Welding looks sloppy but I needed the material so I could grind down a chamfer

http://i560.photobucket.com/albums/s...psgahwynnk.jpg

This took a while, lots of blueing and grinding until I got it to fit in there snug.

http://i560.photobucket.com/albums/s...psenlp9bhz.jpg

Then my "sealent". The carbon buildup from the intake manifold. Slobbered it on, clamped in the sensor then blow torched it until it cauterized.

http://i560.photobucket.com/albums/s...psibvfiuez.jpg


Sensor installed. You can also see the Test plate I put over the egr port, made out of 1/4" steel.
http://i560.photobucket.com/albums/s...psfcqq4rp6.jpg

The stuck wastegate flappet.

http://i560.photobucket.com/albums/s...psgbp8bnmt.jpg

At this point I realized I had to take off the turbo.

http://i560.photobucket.com/albums/s...psf1elsz1e.jpg
http://i560.photobucket.com/albums/s...pstzxw1xaa.jpg

I got it freed up but it was obvious it had to be removed, I could have sat there all day moving it back and forth but it wasn't going to help.

http://i560.photobucket.com/albums/s...ps4gwxwigi.jpg

Nice Work
 

[No the EGR IS the Problem! The Nasty Exhaust gases and debris mix with ANY
form of lubricant (Say the tiny bit that escapes the Valve Cover from the line
that feeds in UpStream of the Turbo's intake) and forms the Nasty paste like
goo that you found all over your intake system.]

The EGR goo will solidify and block Air (Pressure and Vacuum) passages and
sensors everywhere it touches.

Yeah, I may be leaving those "test plates" on for a undetermined amount of time :)

Okay guys, got the turbo all put back together and installed, produces a healthy 14psi under heavy load but egts only get to about 500f, and is still a little doggy. Definitely heading in the right direction!

What's the next step? Fueling?

Do you see about 5psi by 2000rpm if you go heavy off the line? Do you see smoke under load?

There's a laundry list of things to consider including:

- fuel filters
- ALDA signal
- ALDA response
- IP timing
- cam timing/chain elongation

Sixto
MB-less

That port you pointed to needs to be spotless, and connected to the Alda under the intake. The line, and any valves it passes through on the way to the alda need to be clear. This will improve your shifting response also.

I'll see 5psi pretty much off idle. 14 psi at full load. No smoke at all. Still a 30second 0-60. :(

I eliminated all those transducers, since they don't go to anything anymore. What are these two vacuum lines for? The one I'm holding has a filter on it..

Will do
If the alda isn't functioning could it cause a 30 second 0-60?

I just removed the alda, oh my god WHAT A DIFFERENCE! My 30 second 0-60 is about 14 now, very, very happy! It will really blow black smoke if you rev it at idle, but only smokes a little on take off. Full throttle nets about 14psi still and maybe 850f on the egts.

I think there is still room for improvement, even though the fuel filters look right out of the box im going to replace them per everyone's suggestion lol

Transmission shifts way better now, not sure why, must have inadvertently fixed a connection.

Off idle acceleration is IMPRESSIVE! Any gains to be seen are defiantly on the top end.

Acceleration is very linear, like a car should be. I've read that is the result of removing the alda.