Major problem! HELP!!!!

[dazsir]

Just recently got my car back after fitting a T04R and having it mapped. :InLove
Went out on friday of last week, to take my mate out for a spin, all was going well until.....

It was boosting hard (around 0.7bar, so the tubby was getting into its stride), then all of a sudden the power and boost dropped, my initial thought was an intercooler pipe had popped off, so we limped home, up hills it was struggling to pull any power (no boost either).  Got back none of the pipes were lose, apart from one - but it was so hot, I could not take it off!!!
I set off home, then all of a sudden the wastegate opened and ALL of the exhaust gases were passing through the screamer pipe!
Recently I removed the wastegate and hooked it up to a pressurised air source to check and it works spot on, there is no damage to the diagphragm or poppet valve.
Fitted it all back to together and started the car, it runs, but idles rougly, lots of rich smoke comes out of the exhaust (normal on idle, I think) - my mate the observation that one of the lights (as it was dark) was flickering (nearside) - so could it be an electrical fault, or am I just deluding myself?

Any help would be appreciated!

Thanks

[antnicuk]

try doing the DIY compression test,  make sure that you have compression on both rotors.  There are lots threads on how to do this, have a search

[peterwolds]

Darren did you speak to lindop ?

[BlitzBoy]

A few more ideas
if its rough then double check all the intercooler pipes are on correctly and couplers sounds like a boost leak somewhere, also check the vacuum hose to the MAP sensor is on correctly and is not split.

[dazsir]

Arse. just done the champagne test, its boogered, it failed it miserably!

Started it, bubbles began to rise in the coolant in the filler cap.  That would explain the sudden opening of the wastegate as the water would become a vapour and push very hard against the poppet valve.

Arse. :mad:

[bin liner]

does it **** water out after a drive? Are you topping water up? Hard to start in the morning?  Has it been bled after turbo change as u could have air escaping out of the system, hence positive champagne test?

[Grizzly]

Does it push water out when cold? usually if the Pipes go hard as soon as you start the car from cold (with the caps on) its goosed.

[kev-yorks]

Guess the new turbo setup was just too much for it Daz. You\'ll be looking forward to a busy winter now.
Kevin

[peterwolds]

gutted for you Darren after all that hard work

[dazsir]

Hi guys thanks for the kind words, yes the pipes go hard, water is missing, the water has little bits of oil in it and some black stuff.  It smells of combustion (technical nose - I am a chemist!).
Pah it looks like a rebuild, although a Hayward engine looks good with such a favourable warranty!
Whatever the work needed I will do the spannering and let the guys at Lindop set it up!

Getting a workshop made at home with a nice car port next to it for working on the car, will have a kettle, tv, etc. For anyone who wants to come and help!

Thanks

[dazsir]

TBH I might consider breaking it up, as there are a lot of high quality parts, and I am a bit skint at the moment.

[nikp]

Well, if you have a set of 1600\'s, then consider me for first dibs please!

(Sorry for your issues! :p)

[dazsir]

I have a very comprehensive fuel system, KG Parts Extreme, that I would be selling if I do break it!

Thanks

[leon]

Well if your writing it off, sombody has recently has had a good experiance using sealup. Guess it all depends on how badly its drinking water

http://www.motorshop1.co.uk/sealup.htm

[memski]

Gutted for you Daz