issues turboing 2.8 lux

[gotta_b_a_lux]

hey all, currently turboing my 2.8 D with a ct20, went to bolt it on tonight an i cant get the three bolts an the stud to wind in enough into the block on the left hand side (into the holes that have never been used) ive hit it with crc spray several times tried cleanin them out with a screw driver an a rag, etc. just wondered if anyone else had this issue?

at this stage im goin to get a tap kit in the mornin an re-tap them

any info greatly appreciated

cheers

Chris

[berad]

How far do they go in?

If it is an acceptable amount just cut the stud, or as you said retap it.

[gotta_b_a_lux]

all good, i just re-taped them an they went in easy as.

its all up an runnning now, just wondering how important it is to run my rocker cover breather to the low pressure side of the intake now?

i just left it where it was for now, i didnt realy want oil going through my intake pipes into the turbo. also in my mates surf his excess oil was running back into his airbox i just dont want this to happen.

cheers

[SIMMO84]

If its plumbed into the high pressure side now you will pressurise the engine and will start blowing seals very shortly.

[Mr DJ]

What SIMMO said, and if your concerned about "blow by" then fit a catch can in line, works well for me

[gotta_b_a_lux]

ok i think ill just run it to a catch can, when you say an inline catch can do you mean the breather just runs into it or? any ideas on plugging the hole where breather used to run to on top of the intake manifold?

Cheers

[Mr DJ]

For catch can plumb breather from rocker --> catch can --> crossever pipe (between air filter & turbo)

To plug the hole, could use a bit of hose with a bolt clamped in 1 end till you work out a permament solution.

[gotta_b_a_lux]

ok ive blocked off the hole in the intake manifold with 2 clamps, a bit of hose an a end stop.

and for now ive just run a breather to a homemade catch can (water bottle).

took it for a run with a mate following me to see how much black smoke is pumping out when giving it to it going up hill an it was coming out a bit heavy as i had wound the screw in 1 full turn prior, so backed it off 1/8 of a turn an went for another run.

but i had to pull over as there was white smoke coming out. when i pulled up there was oil running down my exhaust. it was leaking where the dump flange meets the exhaust pipe. but still i cant figure out where the oil is comin from? i drove it home easier an it was fine the whole way home.

any ideas as to whats goin on? only leaks oil when giving it some curry.

cheers

[Mr DJ]

Is the oil on the inside exiting at the dump/exhaust join, or leaking down the outside of the dump ?

Have you plumbed the oil inlet & return up correctly and checked they are not blocked or partially blocked with sludge?

[gotta_b_a_lux]

yes the oil is exiting at the dump/exhaust join.

i think ive plumbed it right.

i am yet to check that they are blocked waiting for it to cool down a bit.

here are some pics, hope this helps you help me...



also i noticed oil coming out of where the bar that runs from the wastegate to the turbo, goes into the side of the turbo as seen below on the right..

[Mr DJ]

Hmmmm, my guess is the seals around the shaft are cactus and would need to be rebuilt

[gotta_b_a_lux]

so the seals inside the turbo?

how much am i lookin at roughly to get that done?

i bought it a week ago off this forum in apparently excellent condition...

[Mr DJ]

Yea, I would say the seals, I can't think of any where else that much oil could come from.

When you accelerate the oil pressure rises, pushing more oil past the seals.

It is possible the seals had been dry and have gotten hard, maybe take it for a few short gentle runs (round the block) and see if it improves with luck.

As for rebuild costs, some on here have bought the rebuild kits and have done it themselves quite cheaply, tho getting it setup wrong can end up very expensive if you have no idea what your doing (possible new engine).

Do some searches, reading, asking and pricing.
A guess would be $400+ for professional rebuild ?

Have a read here, heaps of info on the CT20's .. http://toyotasurf.asn.au/forum/viewtopi ... build+cost

[granborismo]

Geez , looks to be a serious leak,

i just rebuilt my CT20 about a month ago. its relatively easy

shoot this bloke a email if you are prepared to do it yourself, as he can help you out.

just make sure you mark the compressor wheel to the exhaust wheel before you take it apart.

my kit was $155usd

http://www.gpopshop.com/toyotakits.html

[mosus]

looks like the turbo seals to me, that's what mine did. I need to get another Ct20 i have rebuilt i rang around and it was getting steep to get a shop to do it anywhere from $750 - $1100!!

i did get on to a guy who does them cheap he said roughly $400 -$450 if you want pm me and i'll send you his details. What did you do for an oil feed???

[yamaha__308]

Make sure your oil drain from the turbo is as large as possible otherwise the oil will back up and start blowing out past the seals in the turbo and out the dump.

[gotta_b_a_lux]

looks like the turbo seals to me, that's what mine did. I need to get another Ct20 i have rebuilt i rang around and it was getting steep to get a shop to do it anywhere from $750 - $1100!!

i did get on to a guy who does them cheap he said roughly $400 -$450 if you want pm me and i'll send you his details. What did you do for an oil feed???

oil feed in is in the first photo, i had a braided hose made up that goes from a tee between the oil pressure sender an the block into the turbo via a brazed bolt on the end of the tube for the teflon hose to atatch to.

russ, the guy i bought the turbo off was kind enough to swap my turbo over for another one he had at home, its on now an ill have to suss it out tomoro to adjust the fuel, idle, etc.


thanks to everyone else for the info, im sure sooner or later it will need a rebuild.

[gotta_b_a_lux]

well started her up this mornin an thought my windscreen was fogged up, but no just a nice big oil cloud, this turbo leaks worse than the last one, when i took the intake off there was oil all through the front half of the turbo aswell.

i spent the afternoon/evening converting back to my old extractors till i can sort out this turbo business.

depending on what happens i might pm you about the rebuild

Cheers

Chris

[mosus]

Man that sucks! It's the worst feeling when that happens!!!

Yea no worries let me know how you go cheers

[granborismo]

just looking at this picture again, and assuming this red + black section is your oil drain.

i almost looks like your T peice is way too high, and is the black pipe

your altenator drain? looks to be pointing up instead of down.

i have mine setup way lower, like right at the sump..

this could be causing the issue as it seems a pretty excessive amount of oil.

it just doesn't quite look right. have you got any better pics..?

[gotta_b_a_lux]

hey mate. Yeh the lines werent hooked up in that photo i just had a bit of hose on each side of the tee. I had only connected the 16mm inside diameter from the turbo to the tee. It was just a progress photo.

This is what the final setup looked like, of course with the turbo on and the drain attached, ive just capped it off for now. I just have the extractors on for now...



Also i went past competition tuning this afternoon an got them to look at it an they couldn't fault the way i set it up...

just waiting to here back from russ, so i can start sorting it out again.

[DR Frankenstine]

hey mate. Yeh the lines werent hooked up in that photo i just had a bit of hose on each side of the tee. I had only connected the 16mm inside diameter from the turbo to the tee. It was just a progress photo.

This is what the final setup looked like, of course with the turbo on and the drain attached, ive just capped it off for now. I just have the extractors on for now...



Also i went past competition tuning this afternoon an got them to look at it an they couldn't fault the way i set it up...

just waiting to here back from russ, so i can start sorting it out again.

The return's not partially blocked at the bottom by any chance

[yamaha__308]

I still think the drain is not big enough and the oil is backing up and blowing through the seals.

I had the same problem with a similiar setup and sizing to yours. I ended up brazing a big (20mm ID?) fitting onto the sump and using the original drain for the alternator.

[gotta_b_a_lux]

i poked a screwy through the drain hole before i fitted the new hoses and it was clear..

I might as well get the drain done direct to the sump so i can totally rule it out.

Any ideas where exactly to tap into the sump? Can i just drill a hole underneath the alternator drain, tap it and wind in a fitting? I can do it on the car...right?

When i picked the turbo up from russ he had a 2.8 engine on a stand with a ct20 on it that i took photos of an ive done the drain the same way he had...

[yamaha__308]

This is how I initially did my drain lines:



And within 5 mins of driving it backed up and blew past the seals.

This was the solution:



I would braze it, as its not real thick to drill and tap a fitting onto it.

[granborismo]

i have also heard that you can get a fitting from turbo glide, that they use in their kits

that apparently just punches itself into the sump and thats it.

[mosus]

Talking to a few people and tapping into the alternator return won't really be succseful because it backs up and pressurises the seals.

What im in the middle of doing it using a fittign like this for the bottom of the turbo:
http://cgi.ebay.com/TOYOTA-CT9-CT12-CT2 ... .m63.l1177

Brazing a nut to the sump for the return and t-piece of the oil pressure switch for feed using speedflow fittings and braided line. should work well.
(in theory!)

[HTH]

brand new ct20's on ebay, round $490

[gotta_b_a_lux]

one of the turbo's is getting rebuilt, should be done by end of next week.

i went to bayside hoses and fittings this afternoon and got the bits i need to bolt to my sump, just have to take the front diff out on the weekend an my steering stabilizer, etc to get the sump out.



cheers

[a1 mech]

Its stange that you've had problems.

Ive put 2X T3 turbos onto mates luxes and have T'd off the alternators feed and drain both times. Both vehicles have had the turbos for well ova 50000km now and no leaks or problems. I ensured the hoses and barbed fittings where all same as original hose diameters.

who knows tho, you can never be sure with buying second hand after all.