Help with testing primary turbo - strange noise

[pixelplay]

I have finally stopped my car from overheating but I had a really hard time getting the turbo inlet pipe back onto the primary turbo. I ended up getting the inlet pipe plastic welded but when getting it back on I think I have cracked the weld again. The main issues I have it that like 10 and 23 connect via a T to the spigot that's damaged and now I have a horrible wining sound that begins around 3k and sounds like a fan belt is trying to escape from the engine.

Its not the belts and this sound cannot be heard if the car is in park or neutral and its revved it only happens as the turbo comes on boost and gets worse as the revs climb so I then back off the throttle to stop it happening.

I am unsure if this is related to the wastegate not opening or the BOV perhaps not working because of the crack in the pipe that was welded. I am fast getting to the point of pulling the manifold again and ordering a Aftermarket inlet pipe as the standard one seems pretty terrible to me. Its to easy to damage it every time you have to remove the manifold and seems to be prone to warping over time and damage to the vacuum spigots.

Anyway I need to try and test things to sort out where the sound is coming from and any help or ideas are welcome.

[boon]

Got access to a compressor?

Take the intake filter off, cram something (a can of beans) in it to seal it up, attach compressor to intake, pressurise intake to 14psi, listen for leaks.

[pixelplay]

 boon said:

Got access to a compressor?

Take the intake filter off, cram something (a can of beans) in it to seal it up, attach compressor to intake, pressurise intake to 14psi, listen for leaks.

Will do and I will let you know the results.

[pixelplay]

Ok I did find three of the pipes were not the best of fits they are the three at the front where what looks like a PVC valve is in the middle of the other two pipes on top of the manifold. I had replaced them but the fit was not the best so I found more pipe now and redid that. The main thing I did find was that what looks to be some sort of right angle crankcase breather pipes that vents from the heads had a crack in it and when it was knocked it leaked. I managed to fix it and make it seal and after that cant really hear anything happening.

The car ran really rough when cold as I moved it into the garage and this morning it hadn't done that at all. The other issue is the the return pipe is the wrong size internally as the OEM one was a lot smaller diametre inside, the new ones about 2x as big in its internal diametre. I will order some replacements for all those pipes but I don't think they are causing the issue I am having.

I will refit the airbox now and see if it will run properly when started.

[pixelplay]

Idles well now but at 2.5k in the revs the scream begins, its exactly like one of the belts is loose and running over the pulley. it never happens unless I am driving the car and I cant make it happen just parked up.

I am wondering if it could be a small boost leak as fitting the TMIC is never easy so in the morning I will check all the pipes again and have a go at running a leak test if that fails.

Edited January 7, 2015 by pixelplay

[boon]

Hrm I do wonder if the primary turbo is on the cusp of ****ting the bed.

[pixelplay]

Yeah I had wondered also about the turbo, when I got the car it had a whistle but that was caused mostly by the inlet pipe being old and stretched, with the newer one that issue is gone but I did have that annoying screech going on.

Anyway when last night I remembered seeing a bolt missing on one of the intercooler pipes close to the secondary turbo and after that my mind suddenly started working properly and I felt like a right idiot. I bolted the bolt back in and the noise is gone

I am going to take it all back off this afternoon and refit all the pipes and double check everything. Also i need to flush the radiator and heater core and top it up with new coolant and also do the engine oil and filter.

The think that had me most stumped last night was that the car seems to be boosting and with a really shagged turbo I would have expected it to run worse or smoke depending on what was wrong of course. Also before I worked on it there was no screeching noise so i suspected something I had done or changed had caused that issue.

The other thing I urgently need to do is to get a timing belt kit as i don't want timing belt or tensioner issues. Where would you go about buying a full kit at a reasonable price?

[pixelplay]

I took the intercooler off today and found two more loose bolts on the bottom of one of the pipes checked all the gaskets and tightened everything and now all the 'cats trying to claw themselves out from under the bonnet' noises are fully gone. I changed the oil, oil filter and also flushed the engine, radiator and heater core to remove any rusty rubbish and refilled with coolant. Its running quite well now and the nest thing to fix will be dealing with the transmission oil and any other old fluids left in the car.