Hey guys, I've got a weird issue here...

So im helping a buddy out by going through a car he just bought. '00 EK Hatch, stock GSR longblock, Victor X, T3/T4 50 trim .63 A/R turbine, Tial wastegate, ~10psi, supposedly dyno'd 360 hp (not sure if wheel or crank).

Ran great, pulled strong all the way through the rev range, but it seemed the turbo was pretty laggy. Wasnt coming on full boost until after 4k or so. Looked around and saw exhaust leaking from pretty much every flange...

So obviously, the plan is to block sand all flange surfaces, and give it all new gaskets, along with redoing the oil feed/drain setup, and just cleaning up the engine bay in general.

So far I've already block sanded the manifold's wastegate and turbo flanges. They were pretty flat, but did have some low spots. All good to go now.

Then i checked the wastegate itself...



Wow, this thing is NOT flat... No part of it is flat. Even the fire ring is warped!

So, what should I do about this? Make it flat? I think I read somewhere that the fire ring is removable, is that true?

Any help would be appreciated! And I'm sure i'll have a few more questions before this is over lol

 

Fire ring should pop right out. Add a little wd 40 and play with it.

 

Ok, good to know!

Should I go ahead and make the flange perfectly flat? Ill probably have to use the belt sander on this one to get it close, then finish it by hand.

 

I would assume yes. Never heard of wanting a flange to be warped.

Is it a legit tial?

 

The does look like a large gap.
How does it look when a gasket installed?
It looks like the contact point on the right side is the bulk of the issue.
Possibly just file that end down if you don't have access to a mill to make it 'like new' flat.

 

It couldn't have looked that great because it was leaking... Lol. I've finished all the other flanges and everything seems good, just this one left.

Also, can anyone point me to somewhere that shows different ways to route oil feed and return lines? Both were run poorly on this setup, and I'm looking for better way to run them.

 

Fire ring could possibly not be seated all the way. It also looks like someone might have tightened one bolt all the way before putting the other in.

Post a pic of what your working with as far as the lines go.

 

Got the fire ring out. Also went ahead and fully dissasembled the WG and cleaned it all up. It sure seams like a real Tial. Very nice quality in everything!


Here is a pic of the engine bay/oil lines. I noted where the main problems I am having are. Also, the drain line runs parrallel to the ground where you see it near the WG dump. The turbo was smoking quite a bit, not sure how much that had to do with the oil line routing or just it being a cheap turbo...

Any advice on rerouting the oil lines is appreciated! I have a few ideas, but would love to hear from some more experienced people!

 

as long as the fire ring seals, nothing else matters

 

The picture I posted should have been in better focus, sorry.

The fire ring was still several thousandths away from touching my straight edge/sanding block.

I have removed the fire ring, and will make the flange perfectly flat all the way across, then reinstall the fire ring, and then I think I will be good to go!

 

Looks like way to much line on the drain from what I see. What angle fittings are on the turbo and oil pan? Looks like less line and two 45 fittings would help. As far as feed, I would route that across fuel rail or under IM and over left side of motor between distributor and head to turbo.

 

I would agree with this UNLESS you have to have the line swing out like that to keep the slope downward. I remember seeing that somewhere. But the 45s should go a long way as long as you can get them to fit.

 

Yeah, that is exactly what I was thinking as far as lines go. Just got a handful of 1/8npt/-4an fittings of varying angles for the feed today from work. I'll see if I can find a couple of 45* -10an fittings...

Right now all 4 fittings on the drain setup are straight.

 

Here my first feed line re-route mockup. This setup is just weird... The line is too short to go around on the drivers side, but its waaaayyy too long to go on the passenger side... There is over a foot of slack in the line how it is set up here. I took the straight 1/8npt-to-4AN fitting out of the turbo and used a 90* 1/8npt fitting, then a 45* 1/8-to-4AN fitting pointing upwards. It works, and doesnt rub on anything too badly, but I still dont like it...

 

I'm Running it on the passenger side.... avoids moving parts .... If it hits stuff just secure it to something

 

Can you route it under the radiator hose?
Then maybe secure the oil line down to tabs and such on the trans.
You can always make the line shorter

 

The wastegate is such a critical part. If mine warps it will be a paper weight.

 

Send it to me of it does

 

I would be worried that the valve seat was compromised. $6,000 engine vs a new wastegate is an easy decision for me.

I have 4 destroyed pistons and 2 messed up ID 1000 injectors if you want those.

 

Send em on down...

Need my address?

 

It might be able to go under the rad hose, but then I think it would be too in the way if the trans needed to be dropped or something. And it cant be shortened, it has crimped ends, not the standard AN style ends.

I think what I am going to do.is make a.short hardline from the turbo to a point that would be easier to reach with the soft line. It only needs to be a couple of inches. Then ill measure what iI need and order a new soft line.

 

lol pm sent

 

I would be careful with that feed line, looks like it's been kinked where it crosses the rad hose.

If it's a line with a teflon liner you can only bend them so far before the inner liner gets compromised.

New lines are pretty cheap and you could get one in the exact length you want, just something to consider.

 

Yes I do plan on getting new lines for both the feed and drain. But right now I am trying to map out the setup with what I've got, so I can see what to order.

The biggest issue right now is the position/location of the oil feed port on the turbo itself. It is just so down in there and at such an odd angle that it is hard to get a line in there. That is why I want to make a short hard line from the turbo inlet.

 

Does anyone have any preferred vendors to get lines from?

Right now im.thinking I need 1 -4AN feed line with 1 straight, and one 90° end.

Then 1. -10AN drain line with one 90° end, and one 45° end.

Lengths TBD. I just need a few websites to search and to give me some price shopping. So far it seems ~$30 for the feed, and ~$50 for the drain.