My 3B Coupe project - Total rebuild

[s2driveruk]

looks great Andy, bet you cant wait to get it mapped

[A80Avant]

nice,

i would definitely get a proper catch tank fitted at some point.

[newsh]

Looking really good Andy!

[AndyP]

Well it's finally all back together and driving even better than ever. The seals on the turbo where shot so the bearing cartridge was replaced along with a clean and balance.









While the turbo was off I took the oppourtunity to do more work on heat insulation as the filter is right next to the turbo. I've re-fitted the hotside blanket I got from Owen Developments, removed because I spilt oil on it Big mistake, I think I had to boil wash it, with dishwasher tablets, 8 times to get oil the oil out of it and stop it smoking when it got hot.

Also made up a heat shield from sheet aluminium to separate the hot side from the air intake, and added some ducting to supply cool air into the air filter.







The result are very noticable, the intake pipework and filter now stay cool to touch whereas before they were getting hot.

When I first put it back together I noticed I was getting a fine mist of oil coming from the oil filler cap, not sure if all the boost leaking into the sump had damaged any of the PCV componants so I replaced the pressure regulating valve and the one way valve. This seems to have cured it as there is now no oil mist

Mapping re-booked for 2 weeks time.

[AndyP]

I would get a vacuum gauge on the turbo inlet to measure how restrictive your air filter setup is.

I'm sure the air filter is not the issue. When JP had this issue he was using a std airbox and it was pumping oil into the inlet to the extent that it was filling the intercooler. Mine has the airbox removed and a huge K&N cone filter fitted. There was a little oil in the intercooler, an eggcup full? but it's been fitted for a couple of years now, so who knows how long it been there.
I'll call the turbo shop tomorrow and see what they've found.