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Old 08-12-2022, 01:15 PM   #1
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Question New Turbocharger has no boost

I had to overhaul my 1992 5.9 Cummins Diesel and I purchased a new turbocharger, part number HX35W 3538881 and I am getting no boost from it.
It had a Holset 3529883 on it. If I rev the engine up to around 2000 RPM I can get 1 pound of boost.
It's in a Diesel pusher and they don't make those engines easy to get to.
I really need some advise on this.
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Old 08-12-2022, 01:25 PM   #2
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It sounds like your turbo actuator is not working. Why did you replace the turbo?
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Old 08-12-2022, 01:37 PM   #3
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Have you put the engine under load and looked at the boost?
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Old 08-12-2022, 01:41 PM   #4
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Quote:
Originally Posted by Jim2u View Post
I had to overhaul my 1992 5.9 Cummins Diesel and I purchased a new turbocharger, part number HX35W 3538881 and I am getting no boost from it.

It had a Holset 3529883 on it. If I rev the engine up to around 2000 RPM I can get 1 pound of boost.

It's in a Diesel pusher and they don't make those engines easy to get to.

I really need some advise on this.


Are you driving it or just stepping on pedal?
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Old 08-12-2022, 01:44 PM   #5
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Try putting it in gear and using the brake well you step on the gas to put some load on it if you're not doing it that way now.
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Old 08-12-2022, 01:56 PM   #6
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Your , replacement HX35W , manual waste gate turbo should be developing boost at that RPM , and the waste gate should have been adjusted properly from the factory .
I have to ask , where is your boost gauge mounted ? Intake manifold ?
Are all the connections between the turbo the CAC ( Charge Air Cooler ) and the intake manifold tight and in good condition ?
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Old 08-12-2022, 02:51 PM   #7
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I do have the boost guage in the intake manifold. I have tried to hold the brake and push on the throttle. It doesn't seem to make any difference. I checked all the connections going in to and out of the air cooler.
The engine runs like a top, but when I go uphill there is no power. It does better if I don't try to crowd it going uphill.
I replaced the turbo because I blew a hose last summer and fried 2 pistons. The exhaust side of the turbo had aluminum from the pistons stuck to it. I cleaned it all up yesterday and may end up putting the old one back on. It worked great.

Thanks for all of your help on this.

Jim Wilson
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Old 08-12-2022, 07:35 PM   #8
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keep us posted on problem
Thanks
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Old 08-12-2022, 07:41 PM   #9
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Black smoke ?
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Old 08-12-2022, 07:43 PM   #10
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Things to consider :

Gage functioning and or broken tubing to gage?

If thats ok. the waste gate will need to be verified CLOSED alll the way and with preload closed.. ( internal spring of the waste gate will provide the preload

Can you hear the turbo spool up ( high RPM) doing a brake / full throttle in driveway

If all the above seems correct than I would look for leaks from output of turbo to the intake
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Old 08-13-2022, 09:05 AM   #11
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Iím not sure if you have a rotary fuel pump or the inline p7100 fuel pump, bu if memory serves correct the inline fuel pumps had a boost reference line from the intake manifold to the fuel pump to increase fuel under boost. Without the line hooked up they wonít increase fueling. That being said have you inspected the turbo since you put it on.
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Old 08-16-2022, 06:17 AM   #12
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Uh, you won't see much (if any) boost until the engine is under load. Just reving the engine without load isn't going to build boost.

First thing to check is does the turbo spin properly. Next check for air leaks. Finally check to make sure the boost sensor/gauge is working correctly. Monitor live engine data to cross check the gauge.
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Old 08-20-2022, 09:43 AM   #13
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Could this be the wrong Turbocharger?

My engine had a Holset 3529883 Turbo on it and the one that I purchased is a
HX35W 3538881. They look just alike and have the same number of vanes on them, both intake and exhaust.
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Old 08-20-2022, 10:41 AM   #14
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Quote:
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My engine had a Holset 3529883 Turbo on it and the one that I purchased is a
HX35W 3538881. They look just alike and have the same number of vanes on them, both intake and exhaust.
That would be a question to ask Cummins , to see if the HX35W is a replacement for the Holset.
Have you disconnected the wastegate actuator arm to check that the wastegate is full closed when the actuator spring is pulling on the arm ?
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