Hey everyone. First of all this is my first post here, so please dont shoot me anyone. Ive been posting on gmpt and grandamowners club for a long time now. I just got a 2.4 5 speed Grand Am that has been turbo'd / intercooled and I'm looking for some help.

I have all of the information regarding what is on the car right now, and its a garrett t3/t4 turbo with a spearco intercooler, aromotive afpr, rc engineering 320cc injectors, turbo xs bov and boost controller, 2.5" downpipe, 3" cat, 3" catback piping and finally Greddy e-manage is setup for the fuel system.

Onto the issues. No boost in 1st gear, 3-4psi at top of second gear (like 5krpm) and 5 psi at the top of third gear (4500rpm +). I was told by the previous owner that it was set to 9psi at one point but he had it dyno tuned to 5 psi as it was his daily driver. We have tried adjusting the boost using the boost controller and NOTHING changes whether its fully opened or fully closed (the boost controller that is). I'm 90% sure you can't adjust boost pressure with the emanage either and i asked the seller and he said I did.... Anyways my question is is there something wrong with the turbo? It is 2 years old now... Also there are a couple tiny exhaust leaks up front by the turbo maybe that has something to do with it? At wot my EGT gage reads 1200-1300.

A couple other things I noticed... the cooling fan was unplugged so I plugged it back in and now its on all the time. And on the bottom backside of the engine I see two plugs that are not plugged in. Not sure what they are for. And lastly theres no check valve on the MAP sensor and I've seen people do that before... is that something I should do?

I have some pics of my old ga here:
http://www.cardomain.com/id/bobgagt98

Heres what the setup looks like on my new one:
http://www.esbob.com/images/grandam/bob2.jpg


Dont be too harsh on me
-Bob

Well lets start with welcome to the boosted club.

Your boost problem is probably blown gaskets on the turbo, or manifold. You should be able to hit the same boost in all gears. Get your exhaust leaks fixed first. If they are before the turbo they will effect boost. Are you sure the boost controller is hooked up?



FU Tuning

Yeah the boost controller has one line hooked up to a charge pipe right after the turbo and one line hooked up to the turbo... so its for sure hooked up.

I can feel one exhaust leak between the turbo and the downpipe, though the manifold is custom and it looks like it was welded like crap so I might just pull off the turbo and manifold then get the manifold re-welded. I can't use a premade manifold because the way the setup is designed, the turbo would not clear the firewall.

As far as gaskets... what should I change and where can I get a gasket to go between the turbo and exhaust manifold, and between the turbo and the downpipe? I'll take that stuff off and check it out... I should probably check all of the couplers in the charge pipe and get the intercooler pressure tested.

Any other thoughts are appreciated.
Thanks
-Bob

hey man, i am turboing my ga and i was wonder how u mounted ur intercooler? could u take a pick or do u have one of it that i could see just for an idea how to mount mine? thanks.

most likely an exhaust issue (check before the turbo)......... or possibly a clogged cat (to much back pressure)........ or a split in one of your pipe couplers. I had a coupler just like your t/b one (aem elbow) it split on the bottom side of the coupler.... could only see 3-5 psi, and you couldnt see the split till you took it off (split on the seam)

If your not happy with your manifold, you can always pull it, and take it/ship it to a company that makes manifolds...... since they will have yours for a template, it should be easy for them.




SPD RCR Z - '02 Z24 420whp
SLO GOAT - '04 GTO 305whp
W41 BOI - '78 Buick Opel Isuzu W41 Swap

"Yeah the boost controller has one line hooked up to a charge pipe right after the turbo and one line hooked up to the turbo... so its for sure hooked up."

That doesnt sound rite,one end should be to the wastegate.

It is hooked up to the wastegate. Yeah the car DEFINETELY needs the manifold re-welded I'm not sure where but its definetely leaking there. The car has a magnaflow 3" cat on it and 3" pipe all the way back so I'm pretty sure the cat isn't clogged.

I'm going to check all the couplers but this week maybe I'll pull off the the turbo and manifold to check it out. I'll take a couple more pics to show you guys.

Thanks for the help
-Bob