I finished installing the intercooler and took it out for a test run. At first I just tried to build a little boost to make sure it's working. So I lean into it and it builds about 4# but after a second or two it starts going down and I hear a loud wooshing sound, it sounded like I had a blowoff valve. So I go back and check and find that the connection between my blower head unit and the tube leading to the IC was not on right. So I try to mate it best I can and go out for another run, ever since then the car makes NO boost at all. If I punch it in first it may get up to 1# but I can floor it in all other gears and my boost gauge stays right at zero. From what I can tell all the other connection are in tact. What could be the problem? Do I need better elbows and tubing? Better clamps?

After that I put back the original vortech discharge tubing and it builds boost just fine. So what do you think could be the problem???I don't have much experience diagnosing intercooler issues.

 

Boost leak is my vote, espicially if the original builds boost. Do you have an air compressor in your garage handy? If not it'll be worth getting one just as a leak finder.

Popular method I found in my DSM days was to wrap a bicycle inner tube over the inlet, clamp it well, and then pressurize the discharge by hooking the air compressor on like 12psi, and then listening for leaks. Good strong clamps and couplings are going to be really handy, or you'll be searching for leaks every day.

Are your IC pipes beaded? It isnt necessary, but I know of some guys that did DIY DSM FMIC setups and before they beaded them (even with great clamps and couplings) they always had leaks. Granted that was at 24psi or so, but the same concept holds true, and might help you out in the long run.

 

Make sure one of the couplers isn't halfway on (top is on, bottom side not on). I've had that problem on car by the throttle body before.

 

All the tubes except the blower discharge are beaded. I believe all of they are all the way on. What do you suggest in terms of clamps are couplers??? I checked out turbohoses.com but holy **** that stuff is expensive just for some hose clamps!!!

 

start the car if you have that big of leak you should be able to feel the air coming out. and if the car runs fine but no boost the leak is before the maf

 

My MAF is relocated to right before the intake elbow. I didn't feel it... maybe I'm missing something. I will go back and check, but is there a way to have colored gas or something like that... I sprayed some carb cleaner around the blower discharge and I don't think it was leaking.

 

Did you have the intercooler tested for leaks? Even with my hose connected, no clamp, It will build boost then blow a tube off. Only way to be sure. Clamp off at the t-body then plumb into the discharge. Use a air compressor to test for leaks. It would take a big *** leak to not make boost.