BennehBoy's D2 adventure

Triple checked all hoses (vac, boost, intake, breathers), all good and tight with no leaks.

Checked exhaust & inlet manifold nut/bolt torques.

Modulator is a year old and have no reason to suspect is duff, but who knows

Turbo wastegate is operating freely (less than yar old hybrid unit), no change to position of the locknuts on the wastegate actuator arm - they are paint marked in place.

MAF values look good.

I'll record some live data on the next drive.

Done another hundred miles and it seems to be a bit pokier, think the reduced boost must be down to the better flow of the new exhaust manifold.... Panic almost over will see what its like after another 500 then rethink

Better flowing manifold should not lower boost pressure

MJI said:

Better flowing manifold should not lower boost pressure

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Yeah I guess I hadn't thought that one through well enough.

Still at a loss on the boost pressure though other than possibly leaky valves.

Could the better flow be boosting pressure, and with the wastegate unchanged the ECU Is registering overboost?

I'm probably wrong, since I don't have a turbocharged engine....

srtgray said:

Could the better flow be boosting pressure, and with the wastegate unchanged the ECU Is registering overboost?

I'm probably wrong, since I don't have a turbocharged engine....

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Nah, no overboost and I have a boost box fitted.

Boost box problem? Just thinking out loud.

srtgray said:

Boost box problem? Just thinking out loud.

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Unlikely, all it does is voltage clamp the MAP output, so it wouldn't cause boost to be limited.

More likely things are....
* wastegate modulator faulty - I'll bypass it to check
* poor compression - wouldn't be great given it's just had 5 new pistons & rings (with dipstick out there's next to no vapour)
* turbo failure/damaged...
* valves leaking
* HG failure - it's brand new
* hose failure (can't hear any wooshing)
* vac hose problems - have replaced them all
* exhaust manifold/turbo gaskets - all seem good, no sooting

Anyhow, lets see how it goes.

Get the engine bedded in for a few thou miles before worrying.i rebuilt a vauxhall engine and it seemed to lack oomph used oil then after a period all seemed ok.

cambridgecockney said:

Get the engine bedded in for a few thou miles before worrying.i rebuilt a vauxhall engine and it seemed to lack oomph used oil then after a period all seemed ok.

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+1 on that... I would certainly recommend that you run it in a bit more for now.

Id say run it more. She'll need at least 1000 to fully bed in and settle again

Cheers for the advice to persevere folks, will see how it goes for a bit. Doesn't appear to be using oil (knock on wood), which is probably good?

Getting a bit worried, coolant level is dropping and have found some sludge in the provent (which is just acting as a catch can at the moment)... beginning to think that despite the pressure test this head has an oil/coolant crack?? Doesn't make any sense though that there would be no oil in the coolant???

****ed off is an understatement.

Anyone got any ideas that don't involve a box of matches and a can of petrol?

The only thing I can think of is the oil cooler heat exchanger, but it looked in good nick when I had the engine apart.

Could easily be the oil cooler, the head pressure tests are preety reliable.

Sure you havent got a coolant leak somewhere ?

200tdi ayre said:

Could easily be the oil cooler, the head pressure tests are preety reliable.

Sure you havent got a coolant leak somewhere ?

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I think the fact there's mayo coming out the breather is testament to it probably being head or exchanger

Ordered a cooler repair kit, but not confident at all

If the coolant pressure relief valve on my header tank cap has failed, could this make coolant pressure higher than oil thus explain why the coolant is in the oil?

Bennehboy said:

****ed off is an understatement.

Anyone got any ideas that don't involve a box of matches and a can of petrol?

The only thing I can think of is the oil cooler heat exchanger, but it looked in good nick when I had the engine apart.

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Again, I've probably got a oil cooler knocking about if you want to give it a try.

Edit, Just seen you've bought a repair kit. Teach me not to read the whole thread first :doh:

Too late, already pushed the button, need to get this sorted ready for Saturday. Cheers for the offer though Aaron.

I reckon it's probably the o-rings between the exchanger and the housing...