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Dustins build thread on the 2.5turbo

  #1  
Old 01-13-2013, 03:59 PM
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Default Dustins build thread on the 2.5turbo

Come to my senses an realized this car has 0 *****. List of repairs injection pump seeps everywere,cyl 5 injector is leaking fuel,couple engine oil leaks, found some bolts missing...Started off inspecting the turbo its a t25 garret.There was very little shaft play an No horizontal play .Took my mighty vac home to do some testing.Found a good spot on the intake to test for boost pressure. Drove it an the highest it went was 5 psi..great..i think it should be atleast double if not more.Time to inspect wastegate...seems to be rather hidden under the turbo.Hooked up good ole migty vac.. Discovered the WG is control by vac an not pressure.. traced vac lines back to a valve an then Ts off back to.. U guessed it a vacuum pump...an the brake booster appeares to run off of this to..hooked the vac gauge up to the main line.had 0.0 vac even at 3000 rpms.. nothing!!... from what info ive gather the egr an the flapperplate an the turbo WG are all controlled by the vac pump ..im thinking of getting rid of the egr the flapper an running my own charge pipe off the turbo..an maybe switching the vac controlled WG to a ebay pressure controlled style WG..an run the pressure line to spot were i Td in to check for boost..Any thoughts?? Forced throw me a bone here....thanks for veiwing i will post pics of my repairs when i figure out how
 
  #2  
Old 01-18-2013, 09:37 PM
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Removed intake..no surprise to find the wonderful sludge the egr left..
 
Attached Thumbnails Dustins build thread on the 2.5turbo-2013-01-18_19-45-12_252.jpg   Dustins build thread on the 2.5turbo-2013-01-18_19-45-44_37.jpg  
  #3  
Old 01-18-2013, 09:52 PM
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Another pic of some more egr soot .Im thinkin of just using a wire brush to clean out the runners in the head an pressure washing the intake...as for the second to pics the copper sealing washers for the injectors were being a pain to get out,I ended up threadin a bolt in the center an workin it b n 4th till they broke free...
 
Attached Thumbnails Dustins build thread on the 2.5turbo-2013-01-18_19-47-11_285.jpg   Dustins build thread on the 2.5turbo-2013-01-18_20-34-10_199.jpg   Dustins build thread on the 2.5turbo-2013-01-18_20-34-24_744.jpg  
  #4  
Old 01-18-2013, 10:03 PM
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Glow pluggs have been inop since i purchased the car..yeah it sucks to used starter fluid to get it runnin every morn.......got some new glowpluggs to install.Gonna Ohm the gp harness tomorrow an try to resolve this.
Any input or should dues while i have the intake off are appreciate
 
Attached Thumbnails Dustins build thread on the 2.5turbo-2013-01-18_21-46-19_613.jpg  
  #5  
Old 01-18-2013, 10:07 PM
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Gonna apologize ahead of time im doin all this posting with my phone...so added words or missing words are gonna surface
 
  #6  
Old 01-19-2013, 07:39 PM
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Someone had almost stripped this bolt out that was on the intake..but i def got lucky.Stopped by the hardware store an picked me up some hardened bolts w/wammy washers ...and picked up a boost gauge.I prefer the older style sunpro it matches with cluster better..an it was 18 bucks
 
Attached Thumbnails Dustins build thread on the 2.5turbo-2013-01-19_13-15-16_239.jpg   Dustins build thread on the 2.5turbo-2013-01-19_13-18-47_977.jpg   Dustins build thread on the 2.5turbo-2013-01-19_13-19-39_5.jpg  
  #7  
Old 01-20-2013, 07:03 AM
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I will disable the vacuum half when i track a good wastegate..id rather reuse the old internal style an install a pressure actuator like u said..but i really wanna make the egr inop ..i definitely see more harm than good on this emission garbage...
 
  #8  
Old 01-20-2013, 07:15 AM
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The first picture is chunks of egr soot that i blasted out with a pressure washer at the car wash...there was alot more but plp was given me strange looks while i taking pictures of the ground lol.Second pic is the oring for the elr an gasket for the for the governor cover plate.
 
Attached Thumbnails Dustins build thread on the 2.5turbo-2013-01-19_16-57-33_74.jpg   Dustins build thread on the 2.5turbo-2013-01-19_13-48-42_151.jpg  
  #9  
Old 01-20-2013, 09:56 AM
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Mb special tool for removing the injector delivery valves... 32 spline, installed new copper washers
 
Attached Thumbnails Dustins build thread on the 2.5turbo-2013-01-19_15-07-51_594.jpg   Dustins build thread on the 2.5turbo-2013-01-19_15-08-00_585.jpg  
  #10  
Old 01-20-2013, 11:47 AM
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First pic is of the inj pump with the elr an cover removed..2nd is the fuel enrichment adjustment ,3rd is idle adjustment.. i marked both with white paint,there both 10mm nuts an just as forced explained in his how too's above the adjustment screw will move when u tighten down the locknut 10mm ..the white paint will visually assist you better.. btw i turned both 2 full turns cc
 
Attached Thumbnails Dustins build thread on the 2.5turbo-2013-01-19_14-17-10_715.jpg   Dustins build thread on the 2.5turbo-2013-01-19_14-18-30_149.jpg   Dustins build thread on the 2.5turbo-2013-01-19_14-23-00_592.jpg  

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