UPDATE:

I'm suspecting that the -no boost- problem I'm currently having is resulting from a bad BOV. Although it was working great before the Turbo rebuild. The loud whining sound that starts exactlty at "0" boost may be the BOV venting. I'll change out the CRV and place it in the BOV location to check for boost hold.

 

He's refering to the nut that holds the compressor wheel on. It isn't the right torque setting. My experience was that the nut spun itself because of the rotation of the shaft and the nut shot through the compressor wheel. Not pretty. Make sure it's tightened good.

Greg

 

Do you mean to say that the 17.5 lbs of torque specified in the instructions are incorrect??. If so, at what torque should the nut be screwed onto the Compressor Wheel??

Thanks.

 

UPDATE:

BOV checked out okay. Next option is to check for boost leak at the Compressor housing(s). Maybe Large snap-ring holding Compressor and Bearing housing together, not expanding all the way in?? Will also check Manifold exhaust gaskets. They weren't in great condition, but weren't causing a leak either before turbo rebuild.

Regardless, loud whine (boost or exhaust leak??) still coming from around Turbo-Manifold area. I'll take them off (3rd time) again tomorrow. I won't rest till the boost problem is solved. Hoorah!!

 

this may have been asked before so i apologize if im asking again, but are you sure this is not all becuase you did not have your turbos rebalanced? I know you said you marked it but...it dosen't seem to be working.

 

I really don't think it has anything to do with an unbalanced set-up. The Primary Turbo is spooling like a crazy mad top. I'm losing the boost to a leak that's located somewhere on the Turbo or Manifold. The loud whine is indicative of a leak. I'll get a better picture tomorrow after I pull them off.

 

I don't think it's the large snap-ring because if it is, you would see oil all over it. However, I don't know what else could it be to tell you the truth.

amel

 

There would only be oil on the Compressor side if I had a leak in the O-Ring and/or in the Plate Seal ( the one that's pressed in). The snap-ring is suppose to hold the Bearing Housing and Compressor Housing together. If the snap-ring is not properly snapped into place, the housings won't create a solid seal, thereby, creating a leak on the Compressor (boost) side.

Other possible causation would be an exhaust leak on the Turbo Manifold or the bolts/retainers that secure the Bearing housing onto the Turbo Manifold. Too much escaping exhaust will decrease Turbo spool which will in turn decrease boost.

 

UPDATE:...
I decided to ship my Twins last week to Turbo City after numerous attempts (took them off/on 7 times) to diagnose my primary turbo whine failed. Instructions were given to TC to disassemble all the components and to inspect for damage of all the turbo kit components I installed. I also wanted TC to balance both sets of turbo wheels/shafts.

They arrived at TC on Wed. Gary w/TC called me yesterday (within 24 hours) and told me they were ready to be shipped out. He advised me that the only damaged parts he found was the Plate Seal on the Primary Turbo which was cracked. He stated that it would've leaked oil had the Turbo been put to use. He also found that the Compressor Wheel Nuts had been over-tightened on both Turbos. I suspected that from the get go!!

Additionally, he felt that the the Primary Turbine Wheel was a little eatin-up, so he had to replace it in order to achieve a good proper balance.

All in all, TC's charge for all the work and parts used in the "rebuild" was only $70.00 plus shipping. (35.00 per Turbo). This amount also includes the balance of both Turbos. Not a bad price at all. I should get them back by mid-week and will istall them next week-end.

I was expecting worse news from TC, so I jumped the gun and located/bought a set of twins last week that have only 42K miles on them. If everything goes well with my rebuilt Twins from TC, I'll sell the recently purchased Twins in our classified ads section.

 

Hey,

I was wondering what happened to this thread.

In the end was there anything you could have done on the rebuild to avoid all this trouble?

Did TC tell you that the turbos were completely out of balace or did they just do the balancing for good measure?

Ian

 

It's apparent that I didn't re-install the primary wheel/shaft on correctly. I may have not kept them aligned as I placed the index marks on them??. Gary told me the Primary Turbos balance was way off. But both Turbos were balanced. It must have been an over-sight on my part.

 

By what degree was it out of balance and what is the tolerance? Did he do a component balance prior to balancing the assembly or just the assembly? I think you responded to that in an earlier PM but I erased that, sorry for asking you twice To what RPM did he spin the assembly for balancing?

I'm just asking all this for the sake of curiosity, not trying to pepper you with questions

$70 for the parts and labor sounds like an awesome deal.

 

Good Questions. I didn't ask Gary for specific tolerances, but he did state that the Primary Turbo was way out of whack. I think he may have marked them before the balance and then compared his index marks to the final wheel to wheel resting points after the balance?? I didn't ask at what rpm they were balanced, but I think I'll call him on Monday and find out. I'll post his answer then. I wonder if balancing procedures call for the wheels to have to be spun close to 100K rpms?? I doubt it.


$70 is a damn good deal. I should have shipped them out when I pulled them off the first time. It would have saved me a lot of time and effort. I should be driving the car right now in stead of waiting for the Turbos to get here for yet another install!!

 

I know that some companies spin their turbos to about 5k rpm to do the dynamic balance. I believe the component balances are done at a much lower speed. Motorsport turbos, aka race turbos are spun at a much higher speed, I don't know how high exactly.

Interesting, I never really thought about rotating the wheels relative to each other for balancing. On a turbo that has a threaded compressor wheel you can't do that because you would be changing the seating torque. On those turbos you actually grind material off the nose of the wheel. If you marked your wheels I just don't see how they could have gone out of whack and caused such an imbalance.

 

Yeah I'm still confused as to how I dropped the ball by not placing accurate index alingnment marks?? I triple checked all my precedures. A while ago I checked the video footage of the rebuild and it captured the alignment marks before and after the rebuild. Everything looked perfect.

 

Just got my Turbos back from Turbo City. They look brand new! Wish my digi cam was workng to post a few pics.

The Turbine Wheels look like they've been beaded/blasted and the Turbine Wheel Covers look like they've been replaced with new ones. They actually replaced the Primary Turbo Turbine Wheel/Shaft with another set. And both Turbos were balanced. I'll install them when I get home from work and post my results later this evening.

 

Any updates? Sorry to hear the DIY approach failed.

 

I'll find out in the morning when I install the Turbos.

 

Got the Turbos installed this morning. I replaced the old manifold gaskets with a new set from Malloy. I also replaced the OEM broken DP 02 sensor with a Bosch unit I bought at AZone .

She's back!!

 

How does it feel and run? Does it have good boost pattern etc? Any smoke?

Amel

 

Hey Amel. It really feels/sounds no different than before the rebuild. So far absolutely no indication of smoke at boost. I only took her WOT once (no smoke, and it felt pretty good!) but I'm going to put at least 200 miles before I start working the Turbos a little hard.

It was really good to see my dual S/S tips maintain their shine after a good drive. I use to have to wipe them clean every 10 miles or so (i'm **** that way ) cause they'd get dirty/smuggy as a result of the Turbos leaking oil.

EDIT: One thing I failed to mention was that at WOT at secondary transition, I did hit 11psi. I'll be looking to buy a boost controller OR a PFC soon.

 

Nice!!! I'm so glad it worked out good finnaly. So what are you going to do with that other set of yours?

 

congrats! glad to hear she's back!!!

 

Thanks. I intend to sell them on the Forum/Class-Ads. The Turbos only have 42K miles, so I'm sure they'll go pretty fast.


Thanks Bro. Now it's time to put the Brembos and the engine bling bling on.

 

how much will you be asking for the twins?

Amel