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  1. #1
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    Talking Work Has Finished...

    I've started the 19T conversion.... I'm not rushing the job, plan is two maybe three days... I can't spanner as fast as i used to, thanks to a dodgy body, but hey, it'll get done... no rush... she's sorned for another 21 days anyway....

    I'll be in the garage.... drinking tea, with an oil patch on my head from all the scratching... The most technical engine I've worked on in the past is a V6 Cologne!!

    Learning curve it is then.....

    I bet pedro's at the pod....
    Last edited by PaulZX; Wednesday 13th May 2009 at 11:28.

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    so you,ll have that 15g going spare soon then matey?
    how are you going to manage waiting 18 days for your first test drive?
    1991 retro alfa romeo 75

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  4. #3
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    a 19t just isn't laggy enough
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    Quote Originally Posted by TheFlyingFridgeMover View Post
    I bet pedro's at the pod....
    Yep but still keeping an eye on you lol, good luck with it and keep us informedM
    . My phone still works sometimes if u need any help

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    cool cheers matey, should I have been seeing oil in the air pipe that goes into the top of the turbo? Not alot of it, but there was some there....

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    Thats completely normal. Removed quite a bit of oily sludge from a 406 HDi turbo today
    2008 Ford Mondeo Titanium
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    Quote Originally Posted by TheFlyingFridgeMover View Post
    cool cheers matey, should I have been seeing oil in the air pipe that goes into the top of the turbo? Not alot of it, but there was some there....
    Ive yet to see a car with out a bit of oil in the intercooler pipes

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    kewl, kewl.... good to know that's normal....

    I had a little trouble with the silly allen bolts on the oil return pipe, but got it in the end....

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    You can vent the PCV to atmosphere to stop the discharge of oily residue in the intercooler pipework. You will need to blank off the small vac pipe from the side of the inlet manifold also. The two pipes leading to the PTC in the MAF pipe just before the turbo are the ones you will be working on. Blank off the PTC in the MAF pipe but leave it electrically connected. You can then vent the larger pipe from the PCV to atmosphere with an extension in the pipe down to the ground underneath the car preferably away from the engine bay to stop unwanted fumes in the cabin. The small vac pipe can then be blanked off at the inlet manifold end to stop any unwanted vac/boost leaks.

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    Duly noted Alan, cheers...

    Curent stage:

    I've got the turbo & exhaust manifold off now, so I'm just waiting for a cheque to clear in the bank, before I can buy the 2004 S60R manifold, and put that on before I mount the new turbo. I've gotta get a set of gaskets for the exhaust manifold-to-engine mounting....

    I'm amazed at how well all the nuts and bolts have come off so far. Apart from two allen bolts on the oil return pipe to turbo flange, that were a bugger to turn coz of limited space... (I chopped a 5mm allen key by about 40mm and used a ring spanner to turn it, and it worked splendidly), it's all came off really well (touch wood) so far...

    I've only got 8 bolts to take off, to remove the exhaust downpipe from the rest of the system, then I' waiting for the exhaust manifold and gaskets to turn up before re-assemble time.

    Plan is to be finished & ready for road before the end of April, so there's no rush as yet. I'll be taking her to high-tech motorsports in Cradely heath in the first week of May, for a full diagnostic check and fuel setup on the rolling road, so if there's anyone local that wants to tag along, you'll be more than welcome.

    Anyway, I'm done for now, I'll split the exhaust at some point this week, but that's all that's needed until the rebuild starts in about ten days time....

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    will you be running this on the standard ECU then?
    i dont know anything about this conversion and whats involved.
    1991 retro alfa romeo 75

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    yeah I'm gonna try it on what could be a standard ecu, but the tabs on it have opened at some point, so it could have been played with, I havn't got a clue. I control the boost with an mbc, I'll be getting a rolling road setup within the first week of may, to be sure she's runnig ok, and make my mind up about the ecu after that. If she's running ok, with the power I want, there's no point in remapping, but if it's below the minimum I'm expecting, then obviously it's a route I have to check out...

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    Have you got a afr fitted if not i would think about having one its better to be safe then sorry

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    afr? wots that then?

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    I'm guessing he means something like this...

    http://cgi.ebay.co.uk/NEW-52mm-DIGIT...09111001r36791

    If I'm wrong, I apologise, just going off somehwere to mind my own business .... "TAXI!"
    94 855 T5 manual

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    woz (Sunday 12th April 2009)

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    Quote Originally Posted by Rob S View Post
    I'm guessing he means something like this...

    http://cgi.ebay.co.uk/NEW-52mm-DIGIT...09111001r36791

    If I'm wrong, I apologise, just going off somehwere to mind my own business .... "TAXI!"
    if that's the case, then no, I aint got one of them, but I am planning on getting an apexi boost conroller soon, if that's anything close..

    I'm new to all this turbo tuning, gimme a cologne V6 and i'm usually happy.....

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    Yep after 2 2.8 Capri's and 3 4x4 Sierra's, I know just where you're coming from!
    94 855 T5 manual

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  20. #17
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    Picture update ..... mini how-to....

    Starting point...


    Removed battery, airbox, and strut brace...


    Drain coolant....


    Remove intercooler pipes from top of turbo


    remove the two heat sheilds (grrrrrrr, not an easy task)


    the 15g turbo unit....


    remove the oil feed and coolant feed pipes...


    oil return pipe with the stupid allen bolts...


    Pipe off, then it's the bottom bolt on the downpipe, and the two bottom bolts on the manifold flange...


    Turbo out....


    Standard exhaust Manifold off next


    Where the exhaust manifold bolts on...


    Exhaust manifold gaskets, 2 of the 5 were completely fubard, and the other 3 are almost completely burnt out.... Turning out to be a good job I did this....


    Blue injectors fitted with new O-Rings...


    I've still got to take the standard downpipe off the exhaust system, but once that's done, I'm on hold for a week, waiting for money to clear in the bank before I can buy the new manifold, gaskets, and de-cat pipe. I'll also be buying the pipework for the reverse flow intercooler setup. Hopefully, I'll be back at it around the 20th, hoping to be finished about a week after, well in time for taxing her on the 1st of May.

    Then it's off to the rolling road for a full diagnostic check, and happy days should be the outcome.

    I think it's officially the half-way point now.
    Last edited by PaulZX; Sunday 12th April 2009 at 14:03.

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    your getting there tffm......

    let me know when you go cradley heath as its round the corner from my garage.

    i'll tag along.

    chad
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  23. #19
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    cool, will do mate.... I'll be seeing you before then anyway....

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    Quote Originally Posted by TheFlyingFridgeMover View Post
    afr? wots that then?
    its a air to fuel ratio gauge/monitor

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