I am having a problem with my '91 TII engine I just bought. It is boosting to nearly 1 bar (14psi), which is WAY to much for the stock motor/ems. I am not getting a fuel cut for some unknown reason.

Im guessing the cause for the outragous boosting is my high flowing exhaust. Does anyone have any tips that are not going to cost me an arm and a leg to do?

I really want to drive my TII on the turbo, its so frustrating having to drive it under 4000rpm!

Any help would be greatly appriciated.

 

is your ecu chipped to get rid of the factory boost cut?

is your wastegate functioning at all?

 

As far as I know the ECU is completely stock.

What would be the easiest way to check if the wastegate is opening at all?

 

A previous owner must have installed a fuel cut defender to allow boost to exceed the factory 8.6psi fuel cut. It'll be a little box plugged into the boost sensor.
Yes your exhaust (3"?) is probably the reason for the excessive boost. You need to pull the turbo and port the wastegate. Do a search, there's heaps of info on it here.
Check the operation of the wastegate just in case. Pull the wastegate actuator hose off and attach a hand pump with a pressure gauge. Apply pressure to the actuator and watch to see when the rod starts to move outwards. It should be at about 5-6psi.

 

How hard is it to remove the stock S5 (91) turbo?

Does anyone know where a how-to, preferably with pictures on how to remove the turbo?

I found a place here in Adelaide that will port the wastegate for AU$120 (US$50). Is that a reasonable price?