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  1. #21
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  2. #22
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    How bout the diaphragm in the recirculation valve.....

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    I think I might just take the whole turbo off. That way I'll be able to give it a proper check over. I know it has previously been re built. The noise is not there till about 70/80% throttle. Let's hope the bolts come off easily. Will give them a good soaking first.
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  4. #24
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    I had a very similar issue and it was the cbv valve. The diaphragm was intact it was infact boost escaping between the mating surface of the turbo and valve cover. It is a poor design in my opinion because the valve cover is thin soft metal and easily warps. I got a properfekt cbv which is made from billet aluminium and has 2 o ring seals much like the forge one but half the price and it is night and day over the standard valve. I actually checked a spare 16t I have lying around and it has the exact same issue. I would be checking this. I sprayed some soapy water on the cbv housing and attached a small hand pump to the cbv vacuum line and pressurised it to diagnose.

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  5. #25
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    Quote Originally Posted by Timo. View Post
    I think I might just take the whole turbo off. That way I'll be able to give it a proper check over. I know it has previously been re built. The noise is not there till about 70/80% throttle. Let's hope the bolts come off easily. Will give them a good soaking first.
    I thought it had been apart as there is a marking on one of the compressor vanes.

    As the guys have said check the CBV valve too.
    Last edited by Dangerous Dave; Tuesday 19th May 2020 at 13:56.
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
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  6. #26
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    Glad to see visually turbo vanes etc looking in good condition... keep us posted on the investigation!

  7. #27
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    CBV rubber in very good condition. Surprised no gasket between the turbo and the cover. Nuts were not very tight.

    Turbo was a total git to get off. I left the hot side of things on as I looked at the nuts and thought they would never come off.

    Stand by for pics of turbo internals....
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  8. #28
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    Name:  turboair1.jpeg
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    If you look at the edges of the intake vanes you can see some of them and curled down......... If you see what I mean....
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  9. #29
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    The cbv outer edge works as a gasket. It is a poor design and 99.9% certain it is your problem especially after seeing what look like very good condition turbo internals.

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  10. #30
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    Pressurise the vacuum line on the cbv and if it doesnt hold pressure you have your problem

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  11. #31
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    Name:  IMG-20200519-WA0014.jpeg
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    It's in pieces now. Rebuild kit ordered.
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  12. #32
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    Quote Originally Posted by Gaz View Post
    Pressurise the vacuum line on the cbv and if it doesnt hold pressure you have your problem

    Sent from my SM-G960F using Tapatalk
    Will do. Does seem to be a lot of oil underneath where the CBV is like it's been leaking downwards from there.
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    Quote Originally Posted by Gaz View Post
    Pressurise the vacuum line on the cbv and if it doesnt hold pressure you have your problem

    Sent from my SM-G960F using Tapatalk
    Yeah, it leaks. The diaphragm appears in good nick. Sounds like it's leaking round the edges... Maybe need some gasket sealant type stuff.
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  14. #34
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    Nice disassembly

    Make sure you ordered the right rebuild kit as there are two types (flatback and superback, yours should be a superback)

    You can put the CBV case on some wood and tap it on the top with a hammer to make the bolt flanges rise up a bit, then tap the bolt flanges flat.

    This lowers the sealing shoulder compared to the bolt flanges which in turn should compress the rubber more. I've done it to mine previously.
    Last edited by Dangerous Dave; Tuesday 19th May 2020 at 17:12.
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.
    2004 Sapphire Black S60 D5 - The new daily hack.

  15. #35
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    Quote Originally Posted by Timo. View Post
    Yeah, it leaks. The diaphragm appears in good nick. Sounds like it's leaking round the edges... Maybe need some gasket sealant type stuff.
    Yes this is what I suspected. I would change it for a properfekt one it really is a huge difference. As suggested you can bend the tabs to apply more pressure but you will be doing it again in no time

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    Quote Originally Posted by Dangerous Dave View Post
    Nice disassembly

    Make sure you ordered the right rebuild kit as there are two types (flatback and superback, yours should be a superback)

    You can put the CBV case on some wood and tap it on the top with a hammer to make the bolt flanges rise up a bit, then tap the bolt flanges flat.

    This lowers the sealing shoulder compared to the bolt flanges which in turn should compress the rubber more. I've done it to mine previously.
    Luckily I realised this as I was looking for the kits. Cheers
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  17. #37
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    I'm quite excited on your behalf to see if this solves your issue! Turbo looks in very decent order,

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    Found a missing nut between the exhaust manifold and the hot side of the turbo. Another one was almost finger tight. Nut now replaced and the other tightened up. Previous re con of turbo was clearly done by cowboys. I remember not long after buying the car I traced the BCS pipes and found them connected all wrong. It went so much better after that.... Hoping the rebuild kit comes tomorrow so I can get it back together.
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  19. The Following 3 Users Say Thank You to Timo. For This Useful Post:

    Dangerous Dave (Wednesday 20th May 2020),kmb (Wednesday 20th May 2020),LeeT5 (Friday 22nd May 2020)

  20. #39
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    That sounds promising, hope it solves the long standing problem!

  21. #40
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    I've hammered the CBV case and tested it. No leaks now
    Last edited by Timo.; Wednesday 20th May 2020 at 16:34. Reason: Error
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  22. The Following 3 Users Say Thank You to Timo. For This Useful Post:

    Dangerous Dave (Wednesday 20th May 2020),kmb (Sunday 24th May 2020),LeeT5 (Friday 22nd May 2020)


 

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