Witt's end turbo - oil on the compressor inlet and trying to find the exhaust leak

[alia176]

I'm in the process of solving two minor issues with the turbo and It's been running flawlessly.

I think I have excessive PCV going into the intake of the compressor, which is making its way down the gullet after coating the compressor fins. I'm able to clean the fins easily but this is concerning.

One of the pic shows my air/oil separator solution which does catch a fair amount of PCV oil. I'm wondering if I should NOT let the inlet of the compressor suck the vapor into itself and find another source of vacuum for the left side breather (on top of the valve cover)

Second issue is an exhaust leak that I've always had since the beginning. Since I'm doing a complete ECU harness swap, I took the York and the turbo out for more access to everthing. I DON'T think I have an exhaust leak at the T4 flange gasket but wanted your thoughts based on the pics. I'll put more pics on the second post.

 

[alia176]

More pics of the flange area. Both surfaces seem true using the ruler. I shined a light behind the ruler and saw nothing peak through. When I put it all back, should I use the same style of steel gasket or something different? Do they make thicker gaskets for this application? It goes w/o saying, both surfaces will be shiny clean before the gasket goes on.

 

[alia176]

I'm going to remove the J pipes from the manifold and do an analysis as I think that's where the exhaust leak is originating. Hoping to do this after work today.

I was bummed to see this though....

 

[Toyo Boyo]

should I use the same style of steel gasket or something different? Do they make thicker gaskets for this application?

Thicker gaskets are available. Search for multiple layer or composite, you should find something that fits. Alternatively, sandwich a couple of your existing gaskets back to back?

 

[CJK]

I'm wondering if I should NOT let the inlet of the compressor suck the vapor into itself and find another source of vacuum for the left side breather (on top of the valve cover)

Left side of breather becomes only pathway for crankcase pressure whenever you’re making boost. You don’t need vacuum on it as much as you need a place with pressure lower than the crankcase.

air/oil separator solution

Spend the $200 and put in a real oil catch can. It’s my understanding that these air/oil separators (1) don’t work well ever and (2) only work decent where the air/oil they are separating does not require significant cooling surface area (I.e. the temps are low).

The air/oil/blow-by that is leaving the crankcase via this path is hot and will need significantly more volume of cooling media.

I can pull my intake tube later this week but I’ve been running dual catch cans for a while. Installed a few months after turbo when I noticed there was oil splats on the intake.

 

[alia176]

should I use the same style of steel gasket or something different? Do they make thicker gaskets for this application?

Thicker gaskets are available. Search for multiple layer or composite, you should find something that fits. Alternatively, sandwich a couple of your existing gaskets back to back?

Pls provide a link to a MLS gasket for this application as im coming up empty handed.

 

[alia176]

Left side of breather becomes only pathway for crankcase pressure whenever you’re making boost. You don’t need vacuum on it as much as you need a place with pressure lower than the crankcase.



Spend the $200 and put in a real oil catch can. It’s my understanding that these air/oil separators (1) don’t work well ever and (2) only work decent where the air/oil they are separating does not require significant cooling surface area (I.e. the temps are low).

The air/oil/blow-by that is leaving the crankcase via this path is hot and will need significantly more volume of cooling media.

I can pull my intake tube later this week but I’ve been running dual catch cans for a while. Installed a few months after turbo when I noticed there was oil splats on the intake.

I remember your awesome setup and is the vac piping the same as mine?

 

[Somebodyelse5]

I'm in the process of solving two minor issues with the turbo and It's been running flawlessly.

that's not what flawlessly means

 

[CJK]

that's not what flawlessly means

Reminds me of Princess Bride

“You keep using that word. I do not think it means what you think it means.”

 

[CJK]

I remember your awesome setup and is the vac piping the same as mine?

Yup, same tubing. Throw oil catch can between crankcase and pre-compressor intake tube.

Extra points if you put another one between crankcase and intake manifold on PCV line

 

[alia176]

I got two steel gaskets from Amazon. Looks like the new one is 0.46mm vs 0.39 for the old one. Since these are steel gaskets, are we thinking the old one didn't squish much and 0.39mm is the actual thickness?

 

[Toyo Boyo]

Pls provide a link to a MLS gasket for this application as im coming up empty handed.

MAMBA T4 MULTILAYER TURBO GASKET DIVIDED TWIN SCROLL T04Z T04B UK | eBay UK

MAMBA Garrett T4 Twin Entry divided Turbo Turbine Inlet Gasket. Garrett T4 or T4 type of turbo. Gasket between Turbo to Exhaust manifold. 1 x Gasket. 4 layers of stainless steel SS304.

www.ebay.co.uk

 

[alia176]

MAMBA T4 MULTILAYER TURBO GASKET DIVIDED TWIN SCROLL T04Z T04B UK | eBay UK

MAMBA Garrett T4 Twin Entry divided Turbo Turbine Inlet Gasket. Garrett T4 or T4 type of turbo. Gasket between Turbo to Exhaust manifold. 1 x Gasket. 4 layers of stainless steel SS304.

www.ebay.co.uk

Wow, all the way from U.K.. Thanks very much.

 

[alia176]

I have another update to the exhaust leak and I think I finally found it! The leak has been getting worse since the beginning and I'm still getting P0171 code. Unfortunately, I'm not sure how to go about solving this situation so i'm all ears!

Turns out the exhaust leak is coming from the J pipe flange. I thought I was looking at gasket residue so I sand blasted it then realized it's not gasket residue. If you look closely at the flange pics, you'll see deterioration of the steel itself. The factory donut gasket is doing its best but it's trying to seal up an uneven surface. I'm going to put blue ink all over the flange and try to flatten down the high spots, not sure if that'll stop all the leak or not. I'm also thinking of using a larger exhaust gasket that goes between the flanges as well as using a brand new oem donut gasket.

One suggestion was to build up with some kind of liquid steel epoxy paste, then wait for it to harden and file it down.

I also made a video of the smoke test! New video · Wednesday, Aug 26 - https://photos.app.goo.gl/deycsstGycfH8RdL7

 

[ChargedSHOTaco]

If you look closely at the flange pics, you'll see deterioration of the steel itself.

 

[alia176]

I'm trying a flange gasket on top of the donut gasket concept. The one i bought isn't going to work but i'll return to NAPA for one with a larger ID to allow the donut gasket to poke through which should allow the two flanges to come together nicely. I've been filing the flange to get rid of the high spots but that SS is pretty hard!

 

[reklund5]

That's a bizarre bit of etching on that J-Pipe. I Like the double gasket solution to see what happens.

 

[tmxmotorsports]

That's a bizarre bit of etching on that J-Pipe. I Like the double gasket solution to see what happens.

It is very strange also very strange looking doesn't really look like the steel is going to s*** kinda looks like a coating or gasket material but if it is the steel very odd looking

 

[alia176]

I filed down the high spots, and was hoping if there's any gasket remnants it'd be removed. But no luck, all SS steel which isn't easy to file!

 

[alia176]

It is very strange also very strange looking doesn't really look like the steel is going to s*** kinda looks like a coating or gasket material but if it is the steel very odd looking

I agree.