Rev4 Turbo *mini photoshoot*

[jimGTS]

Kong made 314whp (360ish crank) at 1.2bar with his stock td06, stock injectors and blitz ecu.
eventually going to 410-420 crank at 1.4-1.5bar with more fuel and standalone.

given the new billets higher flow and better spool, i probably wont push much behond 1bar to be honest.

400 should be easily achievable for sure if i ever had the need for it nows its had a refresh

[androo007]

Nice!! Bet it'll flow super nicely. Really excited for you!

[jimGTS]

Nice!! Bet it'll flow super nicely. Really excited for you!

im more excited by the prospect of a screamer pipe again over any huge power gain to be honest, ha.

[jimGTS]

this happened last night.

thought i was going to just remove a few bits while i had a hour or so to kill in preparation as i wont be using the car over the next week or 2 anyways, turns out all nuts/studs came out with ease, so i just carried on and all came out fine.

i definitely feel ive nailed down the best removal order of parts on the stock turbo now.
not that one will be going back on again for a long while.

turbo is still as solid as a rock!
no play, not a single sign of oil seal leakage.
its been a brilliant buy. so will get boxed up and saved.

[jimGTS]

Managed to squeeze some time in today around the xmas festivities

Here's a sneaky pic

[androo007]

Wow!!!!! Exciting stuff Jim looks a million dollars

[C35Rob]

Managed to squeeze some time in today around the xmas festivities

Here's a sneaky pic



Image Replaced With URL For Quote [url]http://url.photobucket.com/albums/v326/jimbob_uk20/rev4%20tubby/A0EBC64A-BBA6-4D1C-B4E0-287778C513F3.jpg[/URL]

that looks awesome, well done mate

[jimGTS]

Thanks guys.
Glad I took my time instead of rushing anything.

Chilled New Years for me.
(was in NYC this time last year!!)

Got a couple of nice xmas presents from the wife, pretty happy.
New Clark workbench. Nothing fancy but good for DIY. Clark vice (not shown) and a sweet Airmaster Compressor for odd jobs.





Here's a little run through with the turbo rebuild.
I used Torco essembly lube.

Parts for the task





For the uprated thrust bearing spacer i needed to ground away around 1mm from the CHRA.


Bearing in


Uprated wider thrust spacer in


Thrust bearing



Oil shield housing with outside wider spacer vs stock
New Oring fitting in CHRA before pressing this shield in, then new C clip clamping it down


New 'piston' ring on the shaft, then the other bearing


Shaft in, twist and click into place


I fitted the oil fittings whilst I was there
Also thanks to the tricks suggested, hair dryer to warm compressor wheel got this on!


Torqued to 1/4 turn as suggested my google!
ZERO shaft play now!!




Compressor housing with new Oring and C clip. Turbine housing on with the turbine clamp, done!







Cleaned up, flat sanded all surfaces and rethreaded the adapter, down pipe, tial wastegate, turbine housing also polished the Tial wastegate slightly


Time to fit with the new nuts, washers, gaskets and studs.
Not alot of room, so needed to remove heatshields





Now unfortunately the downpipe doesn't mate well with the Berk exhaust. Turns out common problem with the Berk, so ordering up a spacer (i.e. an exhaust flange with another gasket). Bit of a hack, but ok with me.
Also need to go to a 22mm ID return oil line, as 19mm i bought won't slot over.
So won't be starting up for another week or 2.

[CalMac]

Looks epic - nice work!

I'm not massively clued up, but do you have to get the turbo balanced with the new internals now?

[jimGTS]

This type of turbo the parts are component balanced.
Meaning the turbine and comp wheel are balanced individually after they are made so don't require balancing once assembled.

[gavsdavs]

Jim, Are you just swapping over the turbo ? Are you doing anything with fuelling, or cooling or ECU ?

It looks awesome as does most of your work, I was just wondering what power you're expecting from that turbo (on its own ?)

[jimGTS]

Hi gav, I won't be going crazy. Only looking to realisitically gain 20-30hp. But turbo has potential for a 100+.

I was considering a ct21 from ATS racing, but the TD06 came up at the right time and because I like my period upgrades, it was a sure thing to go down the bigger route to future proof things.

I'm looking to basically have a more efficient turbo setup, in turn lower egt's and some screamer pipe fun.

For this extra hp. Just looking to increase fuel pressure if need be and retweak my safc2 (map sensor) controller. Nothing mental.

[jimGTS]

After some sturn advice from a few members, i whipped the turbo back off, took it apart and sent off the thrust collars, comp and turbine wheels for a dynamic balance job. Quick turn around so this week I got it back together, and back on in the knowledge it's better balanced.
Everything else bolted together, made my an16 return line and heat sleeved the new coolant and oil lines.
Had a bit of bother with the exhaust mating up and tweaked the downpipe support bracket but all is now well!

Primed again and started it up!! Will install my mani heat shield once I've modded it to fit around the wastegate.

Not given it a drive yet as was raining all day, but looking forward to some dry weather!

Old vs New



Downpipe spacer (aka an exhaust flange)


TD06-20g Billet VS CT20b





Nom Nom

[CalMac]

In the words of MonkyLondon - Very nom nom!

[androo007]

This thread is tipping me over the edge to go gtx billet

[Martin F]

This thread is tipping me over the edge to go gtx billet

How much would that cost, would we get a discount for two ?

Back on topic, another excellent write up Jim, pics are great, shame you don't have forged pistons, would love to see what this turbo would produce at higher boost

[jimGTS]

it has potential, to put it lightly. so whatever happens in the future, itll be enough for my needs im sure.
and I can rebuild it if and when i need to if i choose a different comp wheel.

ill be happy even at 1bar to be honest, more looking forward to some screamer action (tomorrow hopefully!) should make 330-350 at this level really once ive fettled with my fuel pressure and safc2. maybe bit more boost for the strip with some (proven) octane booster.


a laggier turbo ive come to see the potential benefit, this setup will likely be putting less strain/load on the engine in the critical load areas where the oem ecu runs lean (3-4.5k rpm), so should really be a safer setup than the quicker spooling 20b.

less boost (map sensor reading, as it doesnt go on flow, but pressure) and less flow (due to lag) in the mid range should keep afr's not only richer but healthier. my theory anyways.

[androo007]

This thread is tipping me over the edge to go gtx billet

How much would that cost, would we get a discount for two ?

Back on topic, another excellent write up Jim, pics are great, shame you don't have forged pistons, would love to see what this turbo would produce at higher boost

£660 all in. Im going for it. THANKS A LOT JIM, MY GF IS P!SSED AT ME FOR SPENDING MORE

[jimGTS]

your welcome.

[jimGTS]

Fun, fun run.

Screamer action was bloody awesome. Given it's pretty stripped out that side of he car, it's loud!
I put back on stock ecu for testing. Cranked up to 0.9-1bar in the end. Still enough fuel for more. But for B roads it's plenty at the mo.
Fast boost response too!!
With a very tight bov, the turbo flutter was fri88ing awesome.
Hopefully some vids soon.

Very very happy.