Turbo issues

[JaSiN]

Ok, as per all other posts in the last month i have noticed there is heaps about turbo's and their associated issues etc...

As of late there has been a massive power drop in my 96 MU also my exhaust sounds different and the turbo wine (which is a bad sign) are different aswell.

So i thought i would go and get it checked out.

After checking all the basics like air filter etc.. i threw it on the dyno and found its right down on power, only pushing 75hp at the wheels.

ok for the record

56.2 kilowatt = 75.3654414 horsepower (go google conversion )



Bottom line is.... my turbo has had its day, boosting in strange spikes and i am in need of a new one. funny thing is that the gauge says an even 12psi.... but thats wrong! dont be fooled!

ill update with the rest once it happens...


Jas

[Roger]

What about your injectors fuel system?
They may help reduce power.

[JaSiN]

yeah they were ment to be done before i got the car.. but that was about 30,000kms ago.. so might look into the that... but the turbo is the issue.. getting lost of oil slinging around...

just bought my turbo today actually, $1050 from DTS in sailsbury.

i will update more as time goes on... waiting for the turbo to cool down.. then i shal get out the axe...

[JaSiN]

ok well after much fun i have found one majour issue, the turbo isnt set to the right angle... not sure how to deal with this.. but i think that i will just extend the hose and it leave me room for an intercooler....


New turbo


Just a little out! didnt think that would happen... would be perfect if i had an intercooler!


does anyone know if you can rotate the housing? or is that going a little far?

Jas

[muvit madness]

hi jas
not to sure but i cant see why not if all the screw holes align?.
but looking at the pic the diaphragm brackets may not.
trial & error i guess unless you ring IHI direct or if someone else
who has the same turbo knows
Failing that might be the excuse you need to convince the missus
that you need the intercooler set up to connect it all up? after you've
walked around angry for half tha day ;D but don't mention me LOL!!
As thats what i did with the SAS when i blew me budget

cheers
muvit

[JaSiN]

Ok, so now i have noticed that there is a split in the bottom of the intake pipe going to the turbo, so that is going to be hard to get!

has anyone had to replace or remake their intake tube? the one thats directly attached to the turbo? and if so, how did it go?

Ah the fun continues....

[Harry]

Most people have the opposite problem, how to rotate the outlet so they can fit an intercooler.I believe there are some that can't be rotated because of the bearing/ seal setup but I don't know which.
Harry.

[geeves]

The fancy boy racer silicon hose will fix both problems. It comes in a variety of sizes including a concertina flexi version for the outlet and a taper for the inlet. Only problem with the stuff is that its a pretty shinny blue colour.

[JustinW]

What a weekend. (I'll be restrained and not swear) Wizard was on the dyno to be tuned last week and could only get 53kW out of it. With the waste gate disconnected it would only boost to 11psi. It was only boosting to about 7psi under normal driving. Diagnosis - stuffed turbo!! So the game plan for Saturday was my mates were coming over to Tauranga to pick up a new bullbar for the second incarnaton of their winch challenge truck (1985 chasiss and 4.0L Lexus from the first incarnation, a new super charger, a 2003 Hilux cab,Fox coilovers in all four corners, Prado auto so can run PTO winch) then over to Rotorua to change my turbo, then go 4wding on Sunday. We had a look around some of the boy racer outlets looking for some cheap racing seats. At the last one I turned the key and it just went click and drew heaps of current. We tried shorting the starter solinoid, but that didn't help. So after waiting an hour for the AA man and another hour and a half for the tow truck, I took advantage of my AAPlus membership and had it taken to Rotorua. We robbed a starter out of the wrecked Bighorn at his place and had it going again that afternoon, then I pulled the turbo off. Today I pulled the turbo off the wreck and fitted it. Now the bit that really @#$%&(!!! me off is that as I put the rubber reducing elbow that connects the pipe from the airfilter to the inlet side of the turbo I noticed there was something in the elbow. Somehow one of the steel rings that reinforces the end of the plastic crossover pipe to stop it crushing when you do up the hoseclip had found its was into the elbow. There is probably nothing wrong with the turbo I took off, the inlet was just seriously restricted! Now there is no one to blame but me as I took all those pieces out of the box from the wrecker and installed them. I really really wish I'd noticed this when I took the elbow off, not after changing the turbo!! Needless to say it boosts to 10psi now and goes heaps better. It's off to the tuners this week so hopefully I'll have some figures to post later.
By the way, the starter had a collapsed front bearing and the armiture touched the fixed windings and shorted out. I now know the difference between the noise that is "I'm sticking a bit because you have been playing inthe river" and the noise that is "I'm about to die". Also learnt that if the starter dies in an auto the only solution is to tow it home.

[JaSiN]

i have spoken to IHI and they have said that i can undo all the bolts and rotate the housing, but since i have some time up my sleve i might see if i can get a tube made up so i can fit an alternator,

oh and Muvit, the missus agree's... so im going to organise an intercooler soon....

Since my old intake hose is broken (the intake to the turbo) I have ordered a new one, they only have them in melb, so should have it tomo and its about $85 from holden spare parts as the wreckers dont have one.

so im off to see if i can get some hose bent up for the intake...

Jas

[JaSiN]

Ok, after much fun an not luck with most truck and performance shops (that didnt try and sell me a new engine!) i managed to get some Wet Exhaust hose and cut some steel pipe and remake the intake tube (Turbo Input) by reaming out the remaining lumps, and it didnt mind being twisted a few cm's at the top cross intake, so that was good.

I had no luck finding one of thoes intake tubes.. needs to be ordered from Japan i was told! so thats 4 weeks! this is what i ended up with.

Here is the pic for the input tube


and the mess associated once installed (3 hose clamps.. erk..)


After the install was done with what i could find at hand, but im going to have to find some flexi hose or just weld an intake out of some of the bends that i managed to gain.


the main thing i dont like is that the output hose is kinked over not majour but i would like it to sit nice and firm

[geeves]

That kink could lose airflow. I cant see anything wrong with the inlet although using all new clamps or painting them black would of been better
this is the pipes I had in mind
www.simota.com.au/HTML/Fittings_b.html

[JaSiN]

i was thinking about keeping them all the same, but it ended up as it is due to the hassel that was.

i am looking at welding that arch with some of the left over steel bends that i have so its not quite finished, its just good n strong, to get me around at work etc....

did you notice on that link that there is nothing to support 44mm? smallest is 51mm? thats the issues i had today,

Thanks geeves

[JaSiN]

After heaps of running around and people trying to peer into my wallet, i have found that getting a decent tight radius turbo hose is almost impossible, even getting one welded up is sill hit and miss.

After finding no help i managed to E-Bay a 135deg 44mm or 1-3/4" preformed silicone hose from the UK, cost me about $44 including freight which is heaps cheaper than getting any hose here in Australia!!

I managed to shorten the hose and bolt it on, and this is what i came out as.

Oh and Geeves, going down to get some T-Bolts for strength and it should look better too.

[muvit madness]

Hi jas
That looks 100% better than the first attempt
much cleaner fit. good work, ebay is my friend too.

cheers
muvit