MarkSport
Member
Registered: 22nd May 09
User status: Offline
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I want them wheels for my astra so bad 
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Danny W
Organiser: East Midlands
Premium Member
Registered: 14th Nov 05
Location: Northamptonshire
User status: Offline
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Update:
Rear wheels on
Front end built back up and on all 4 wheels 
went out for a quick lap of the block, drives nice & pulls well
Smoke Grey 5 Door
EastMids Regional Events
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Jon_C
Premium Member
Registered: 7th Dec 05
Location: Suffolk
User status: Offline
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Lookin awesome dude. When is she in for mot ? What else you got planned for it?
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Kieran
Premium Member
Registered: 12th Sep 08
Location: Kent
User status: Offline
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 well jel!
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Jamie-C
Member
Registered: 3rd Jun 08
Location: Ballycastle
User status: Offline
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Nice one Danny, she lives at last
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M Sutton
Member
Registered: 11th Jan 03
Location: Northamptonshire
User status: Offline
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Sweet dude!! I really want to see it now.wheels look awesome too 
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Paul_JC
Member
Registered: 28th Jan 09
Location: Corby
User status: Offline
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looking good but you should have fitted metal valves imo  lol hope to see this in the flesh sometime soon
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DansCorsaSXi
Organiser: Yorkshire
Premium Member
Registered: 13th Jan 10
Location: Worksop
User status: Offline
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Top stuff Danny!
Star silver C20XE SXi Project thread
Smoke Grey Corsa GSi Project thread
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vx-scottw
Premium Member
Registered: 8th Feb 11
Location: sheffield
User status: Offline
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at last she's up and running
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Darryl H
Organiser: South Central
Premium Member
Registered: 19th Nov 09
Location: Camberley Drives: Porsche 944
User status: Offline
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Ah glad you got it going Danny! All the effort paid off  Much left before an MOT?
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Crana
Member
Registered: 20th Jan 09
Location: Newcastle
User status: Offline
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ebay link for that loom rap?
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Danny W
Organiser: East Midlands
Premium Member
Registered: 14th Nov 05
Location: Northamptonshire
User status: Offline
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Thanks for all the replies everyone
quote:
Originally posted by Jon_C
Lookin awesome dude. When is she in for mot ? What else you got planned for it?
Cheers Jon, will be going in for mot over xmas when ive got a few days off, for now plans are to get it on the road and usable. but do want a bit more painting doing and possible bigger turbo in the future.
quote:
Originally posted by M Sutton
Sweet dude!! I really want to see it now.wheels look awesome too
thanks Mark, yeah your welcome to pop over and have a look whenever you like buddy.
quote:
Originally posted by Paul_JC
looking good but you should have fitted metal valves imo lol hope to see this in the flesh sometime soon
aha knew someone would spot that, ive got a set of flush fits and a set of metals, i'll fit one or the other when the new tyres are ordered.
quote:
Originally posted by Darryl H
Ah glad you got it going Danny! All the effort paid off Much left before an MOT?
deffo paid off, just a few things, horn and tidy wiring in the car etc. she's a bit smokey too so should get that sorted before an mot.
quote:
Originally posted by Crana
ebay link for that loom rap?
this is the stuff
http://www.ebay.co.uk/itm/270722752320?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649
Update:
Had the car running and been for a few runs round the block but noticed on hot idle she was a bit smokey.
Had a look at the breathers and coolant levels but all is fine. so first thought was a old tired turbo. Had a a look underneath the car and noticed this:
as you can see this is the cause of the smoke, turbo seems to be leaking oil through the core and its burning away through the exhaust system, nothing is leaking into the intercooler.
Im guessing its had a hard life anyway but no oil pressure from the last build couldnt have helped either lol so now its got a good 80psi through it is forcing the oil through the seals.
I've seen a rebuild kit for the kkk turbo's on a few websites so will be ordering tha today.
the kit contains all the seals and o rings, shaft nut, 360 thrust bearing, thrust collar & a K16 Staggered rear oil seal, which helps stop the oil blowing past and into the exhaust on higher boost.
Smoke Grey 5 Door
EastMids Regional Events
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Paul_JC
Member
Registered: 28th Jan 09
Location: Corby
User status: Offline
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ah always something to pop up. hopefully all will be sweet once you've rebuilt the turbo mate
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connollygt30
Member
Registered: 16th Nov 08
Location: West Lothian
User status: Offline
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No smoke no poke mate 
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Jon_C
Premium Member
Registered: 7th Dec 05
Location: Suffolk
User status: Offline
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Any progress with this dude?
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Danny W
Organiser: East Midlands
Premium Member
Registered: 14th Nov 05
Location: Northamptonshire
User status: Offline
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quote:
Originally posted by Jon_C
Any progress with this dude?
Yep a bit of progress so far, now that ive got work, xmas and all the usual things done i'll update
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 shite get everywhere 
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,
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.
More photo's and updates this week when the turbo goes back on the car
Smoke Grey 5 Door
EastMids Regional Events
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Danny W
Organiser: East Midlands
Premium Member
Registered: 14th Nov 05
Location: Northamptonshire
User status: Offline
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sorry for the lack of technical jargon but hopefully the above will help for future reference if someone else wants to rebuild thier old and tired K16
Smoke Grey 5 Door
EastMids Regional Events
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Darryl H
Organiser: South Central
Premium Member
Registered: 19th Nov 09
Location: Camberley Drives: Porsche 944
User status: Offline
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Good work and write up Danny!
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Danny W
Organiser: East Midlands
Premium Member
Registered: 14th Nov 05
Location: Northamptonshire
User status: Offline
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Cheers Darryl, ive got a week off work so hopefully more to come over the next few days
Smoke Grey 5 Door
EastMids Regional Events
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connollygt30
Member
Registered: 16th Nov 08
Location: West Lothian
User status: Offline
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Fair play for giving it a go mate
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Danny W
Organiser: East Midlands
Premium Member
Registered: 14th Nov 05
Location: Northamptonshire
User status: Offline
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Cheers 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
unfortunately rain has stopped play the past couple of days so i havent been able to do much more on the car
Smoke Grey 5 Door
EastMids Regional Events
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corsasportsam
Member
Registered: 29th May 10
Location: west mids
User status: Offline
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good work mate.... love this motor best 5 door one ive seen imo
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Darryl H
Organiser: South Central
Premium Member
Registered: 19th Nov 09
Location: Camberley Drives: Porsche 944
User status: Offline
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Great news there then Danny
I bet you can't wait to get it back on the road now!
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M Sutton
Member
Registered: 11th Jan 03
Location: Northamptonshire
User status: Offline
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Glad youve sorted the turbo problem mate! Fair play for rebuilding it yourself
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Danny W
Organiser: East Midlands
Premium Member
Registered: 14th Nov 05
Location: Northamptonshire
User status: Offline
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Thanks Sam always good tar comments like that! i know there's getting quite a few nice 5 doors out there now
Darryl, yeah im chuffed as hopefully its saved me a bit of cash, too right im itching to go for a drive in it
Cheers Mark yeah i thought id give it a go, if it didnt work i'd have needed a new turbo anyway
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)
Smoke Grey 5 Door
EastMids Regional Events
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