By pass valve on an 88 5kcstq

["Lewis, Gary M" <Gary.Lewis@West.Boeing.com>]

Hi Folks,
I installed a Samco sport TB hose and the generic Bosch 944 bypass valve
(BPV) this weekend.  And I'm having troubles.

The Samco sport hose has a fitting for the BPV.  I had a fitting welded into
the metal turbo intake pipe.  I installed the BPV into the sport hose,
connected the other end to the welded fitting, and ran the vacuum hose to
the back of the mainfold, T-connecting to the second of the fittings at the
rear of the mainfold.  I made sure that the BPV was orientated per Scott
Mo.'s direction.  

Here is the problem:

I have a K24 turbo on the car, and it spools to 1.8 bar  at around 2,600 rpm
BEFORE the addition of the BPV.  After installing the BPV, the thing spools
to 1.8 bar at approx. 3,500.  Worse than the K26.  And I can hear a whoosh,
as if the BPV is opening under boost, causing the turbo to work extra hard
to make 1.8 bar.  Also, after boost returning to idle, the idle drops to 400
rpm, then creeps back to 850 rpm.

This morning, I removed the vacuum line to the BPV to isolate it.  Now the
car won't make 1.4 bar.  But the off boost idle drop is gone.

I am going to remove tha valve and plug the sport hose and metal turbo
intake pipe, to see if I have a leak elsewhere, like the Samco hose.

Here is what I think;

1. I have a bad BPV, or the generic doesn't work with the 5kcstq.
2. I have a vacuum leak under boost other than the BPV, like TB hose, IC,
etc.  (I checked at idle; no leaks).  
3. I plugged the vacuum line into the wrong place or there is a vacuum leak
at the rear intake manifold vacuum line.  However, if the valve had no
vacuum, theoretically it shouldn't open, right?
4.  Some bonehead solution I've overlooked or forgot about.

TIA,

Gary Lewis 
88 5kcstq 1.8 bar 110km Pearl w/Fuchs, K24 turbo, 2-piece EM
86 5kcstqw Sapphire and Platinum, stock 
TransGlobal Financial  (818) 384-7600
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