The Daily 5Door & C20LET project

[Dale]

looking good Danny Glad to see you kept at it

[Danny w]

Thanks for the replies

Cheers Dale, yep its something ive wanted after seeing your car and Pageys etc. maybe i jumped in at the deep end as never done anything like this but im glad i didnt give up

[Danny w]

Oh also noticed that the car does smoke on hot idle, although when i viewed the engine all was fine.
Possibly Seals going on the kkk?

as the turbo unit never ran on proper oil pressure previously, (actually next to no pressure, 35psi max!) could this have done some damage. Now it runs on 80psi im guessing the oils being forced past the seals.

Will need to double check the breathers etc arent blocked and check coolant levels

[viegar0]

this is mint i had a silver 5 door 1.4 16v

[dearing5]

take the boost pipe off the turbo and the exhaust elbow to check for oil..

[Danny w]

checked the breathers and coolant which are fine, just put the car on the ramps and seen this :



yep think the turbo's a lil bit leaky lol nothing is getting into the intercooler though, looks like its just exhaust side. as you can see where the oil is coming out of the downpipe

[Olsrey]

Oils coming from the turbo core by the looks of it.

[Danny w]

yeah, hoping a turbo rebuild kit would fix this.

[Olsrey]

i'd get it rebuilt properly if it was me personally.

[roperstun]

such a shame your've got another set back but fair play to you for keep going with it

[redtopnutta]

oil seal on the exhaust side has gone, common problem

[redtopnutta]

just read it all though and its a very good well built project, unlucky with the first engine though!

[Danny w]

Cheers for the replies lads, heres a little update for you all.
sorry for the lack of technical jargon but hopefully this will help for future reference if someone else wants to rebuild thier old and tired K16


Recieved my turbo rebuild kit so have given it a go.

Started off by removing the unit from the manifold





then stripped the housing off



youve now got the turbo core, this needs to be marked up before anything else is touched, due to turbo's spinning at such a high rpm you dont want them to be out of balence. Mark both ends (nuts & wheels)

then you can take the first nut and wheel of the inlet side



this allows you to pull the shaft and exhaust side out



this was the side that was leaking oil, closer inspection shows the shaft is good and it was the rear seal that had failed.





as you can see above there was a lot of oil deposits and a lot of swarf, which i presume came from the previous engine failures just goes to show this ****e get everywhere :facepalm:

on the opposite side of the turbo once the shaft and wheels are removed you will be left with this:



this plate has another oil seal on & in it and is what the housing is attatched to, you need to remove this by undoing the 4 allen head bolt seen here,
[img]
http://www.corsasport.co.uk/carimages/9482/photo12.JPG[/img]

once removed this is what lies beneath, oil seal, thrust bearing & the bearings for the shaft.



this turbo had no play in it and it was just a rear seal failure that was causing the problem, but due to finding the ammount of swarf i decided to strip all the internals out of the core clean up and replace them




this is the rebuild kit i am using:



to build this back up its reverse of the above taking care to lubricate everything as your go. (sorry for lack of photo's of this) once the core is built up and the shaft/wheels & nuts are all aligned its reccomended to get the balancing checked. I have used a local company for this

More photo's and updates this week when the turbo goes back on the car :thumbs:

[GSi_Online]

Neva thought a 4door corsa could look so nice bud. Nice work

[Danny w]

Thanks Buddy

turbo's all refitted now and had the car running for an hour or so the other afternoon, seems to have done the job as it has cured the leak and it no longer smokes .


Rain has finally cleared up ! so spent a few hours today tiding a few things, re-fitting the interior panels, horn, lights, tow strap and bumper, tried to get all the body work to line up how it should too.









you'll have to excuse the white tape as its just holding the front of the skirt in place while the tigerseal sets overnight .. and tucked away till tomorrow



still havent been able to go for a drive as of yet due to the poorly vauxhall sitting on the drive behind my turbo but here's another video of it running after the turbo rebuild



need to go for a quick blast to make sure all is as it should be then hopefully on to mot, once thats out of the way i'll get it sitting right on the wheels (front end down a tad)

:thumbs:

[Ted_CDTi]

Looking good mate and thats good news that the Turbo rebuild has sorted the problem.

[Danny w]

UPDATE:

Last week my new shaft from LMF arrived, so built it up with the inner & outer CVs although i had to go buy a new outter cv due to braking the other one. Fitted it and took the car out, drove perfect and the shaft stays in the box Result

If anyone needs a nearside short conversion shaft for a nova they can have the one i took off

also while messing about with the car i painted up the cam cover in a ford colour, quite like the look of this and prefer it to the ford graphite on the let engine i took out.




In other news the cars gone away for MOT on monday, while its there i'm having a few bits sorted and hopefully get the rear bumper in paint, after that its on the rolling road to dial in the vernier's & xe inlet cam :thumbs:




Rear end is high in the above photo's as its on -30mm eibach springs at the mo while my brother uses my Gaz rear coilovers .. long story

[M Beirne]

Looks sweet mate