TDI Christmas

Tomaco1

Well-known member
Thats why its silicone, withstands heat better. We reused the original bottom fitting, simply cut the original crimp with a dremel to harvest the fitting and used the supplied hose clamps with new hose to affix. 5 mins.
We did play with the hose length a bit, and preload/twist to get maximum clearance for the return line from turbo and manifold but its quite quick and easy. Not sure how you have a master cyl clearance issue unless you have gone with some custom setup.
Thanks, the brake booster was a custom setup. I just have to switch to an 8” booster from a 9
 

Roverman2010

Well-known member
Fitted my Allisport kit last month, no issues with the kit supplied. I need to refit the old boost pin as way to much fuel now. The 90 is running in the mountains of New Mexico now 8000feet.
The only thing to refit is the get probe as I did have it tapped into the base of the old turbo as there is an inch of cast there.

So where are you guys fitting the probe now?

I must add that the fuel pump has been returned to stock settings, just has the boost pin mod. Also has the double big Allispri IC, But the old girl is running much better. One of the old logging road hills I can now do in 3rd low where 1st low had to be using before.
Love it, thanks
 

Tomaco1

Well-known member
Mines great as well, limited driving so far. I still have to hook the boost gauge, as I crushed the plastic tube and had to start over.
All I could find was copper tubing, other than being tougher to work with, anyone see any other problem using copper?
 

AdamSanta85

Well-known member
Mines great as well, limited driving so far. I still have to hook the boost gauge, as I crushed the plastic tube and had to start over.
All I could find was copper tubing, other than being tougher to work with, anyone see any other problem using copper?
Why not just use regular rubber?
 

Napalm00

Well-known member
Why not just use regular rubber?

Connection to the back of the gauge is 1/8 compression.


Fyi AutoZone/Amazon


This one works well, it has cone shaped instead of football shaped olives. It needs to be about 1 turn past finger tight. I prefer this olive shape
 

AdamSanta85

Well-known member
Connection to the back of the gauge is 1/8 compression.


Fyi AutoZone/Amazon


This one works well, it has cone shaped instead of football shaped olives. It needs to be about 1 turn past finger tight. I prefer this olive shape
O. I just replaced that with a female to male 1/8 barb fitting.
 

Uncle Douglas

Well-known member
Pushing it, with fueling up we saw 21 but then reduced fueling. Not sure where the limits of the head gasket is but didnt want Adam to find out the hard way. The fact that the torque band has been moved so much lower in the rpm range and driveability completely transformed is more the point with these rather than maximizing egts and boost numbers.
 

Tomaco1

Well-known member
Pushing it, with fueling up we saw 21 but then reduced fueling. Not sure where the limits of the head gasket is but didnt want Adam to find out the hard way. The fact that the torque band has been moved so much lower in the rpm range and driveability completely transformed is more the point with these rather than maximizing egts and boost numbers.
What did you leave Adams at?
If you don’t mind me asking.
 

Uncle Douglas

Well-known member
Boost is a function of fueling. You cant make max boost without adequate fueling.
I took his fueling back to less than 1275 degrees on the pyrometer.
Did not touch the wastegate adjustment on the new turbo.
 

Tomaco1

Well-known member
Turned the diaphragm down a quarter turn.
Boost dropped a little, got it on the highway and @ 70mph EGTs were at 1050.
I had to spring for a new 0-30 boost gauge.
 

Tomaco1

Well-known member
Just double checking that there is no gasket between the turbo and the down tube section that comes with it, the 3 stud location
 

AdamSanta85

Well-known member
Just double checking that there is no gasket between the turbo and the down tube section that comes with it, the 3 stud location
If flanges are nice and flat, gasket shouldn't be needed. That being said, a dab of copper RTV wouldn't hurt.
 

donb

Well-known member
I'll see 16-17 psi boost on full load on the biggest hill near my house (which isn't that big). UD and others - do you think this is a safe amount of boost for head gasket concerns? I need to bring the 110 out on the highway to see what the EGT's do.
 
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