Hey guys- during final assembly and testing of my stage 1 velocity kit, I ran into an issue while verifying the wastegate spring pressure.
In testing, the wastegate would not open until 14psi from an air source. During troubleshooting, I found that the wastegate actuator rod was rubbing against a banjo bolt on the block. I pulled the turbo assembly off and tested on my bench- opens around 9psi or so now. Seems about right for this setup.
When reinstalling the unit, I cannot get the damn thing to snug up against the block without it hitting this banjo bolt or an oil line. (This line feeds from the front of the block to the left side.. not sure what its purpose is honestly)
I'm using ARP header studs & cometic crush gaskets in the head. The gaskets don't look too crushed to me, but I'm inexperienced with this type..
If I tighten the top bolts only and snug the bottoms, I can get the turbo unit somewhat aligned, but the actuator rod will still contact this banjo bolt head not allow for proper movement. It also throws off the chargepipe alignment making it a real ***** to get the silicone coupler & clamp installed.
Here are some pics highlighting the issue:
This is the chargepipe alignment which tells me the bottom of the turbo should be closer to the base:
Here is a pic from the previous owner's install of the turbo & header assembly:
His looks to be installed correctly..
Here are two shots showing the actuator rod rubbing on the banjo bolt and the oil line. The second show shows how the actuator bracket was previously clearanced:
Here is a shot of the head with the cometic gaskets:
Here is the turbo / header assembly:
Here is the head showing the two problem areas.. the oil line and the banjo bolt:
Anyone ran into this issue before? I attempted to slide the turbo forward by removing it from the header flange, but the bolt holes are not elongated-- it does not allow for any adjustment.
What is the oil line that goes from the front of the block to the left side used for? Can it be removed?
What is the banjo bolt line for? Can it be removed?
Should I double up on the header gaskets or switch to a different brand / type?
I received the instructions from Jason @ RPM for this kit-- but it looks nothing like the examples shown and it doesn't mention anything about touching oil lines or banjo fittings on the left side of the bike.
In testing, the wastegate would not open until 14psi from an air source. During troubleshooting, I found that the wastegate actuator rod was rubbing against a banjo bolt on the block. I pulled the turbo assembly off and tested on my bench- opens around 9psi or so now. Seems about right for this setup.
When reinstalling the unit, I cannot get the damn thing to snug up against the block without it hitting this banjo bolt or an oil line. (This line feeds from the front of the block to the left side.. not sure what its purpose is honestly)
I'm using ARP header studs & cometic crush gaskets in the head. The gaskets don't look too crushed to me, but I'm inexperienced with this type..
If I tighten the top bolts only and snug the bottoms, I can get the turbo unit somewhat aligned, but the actuator rod will still contact this banjo bolt head not allow for proper movement. It also throws off the chargepipe alignment making it a real ***** to get the silicone coupler & clamp installed.
Here are some pics highlighting the issue:
This is the chargepipe alignment which tells me the bottom of the turbo should be closer to the base:
Here is a pic from the previous owner's install of the turbo & header assembly:
His looks to be installed correctly..
Here are two shots showing the actuator rod rubbing on the banjo bolt and the oil line. The second show shows how the actuator bracket was previously clearanced:
Here is a shot of the head with the cometic gaskets:
Here is the turbo / header assembly:
Here is the head showing the two problem areas.. the oil line and the banjo bolt:
Anyone ran into this issue before? I attempted to slide the turbo forward by removing it from the header flange, but the bolt holes are not elongated-- it does not allow for any adjustment.
What is the oil line that goes from the front of the block to the left side used for? Can it be removed?
What is the banjo bolt line for? Can it be removed?
Should I double up on the header gaskets or switch to a different brand / type?
I received the instructions from Jason @ RPM for this kit-- but it looks nothing like the examples shown and it doesn't mention anything about touching oil lines or banjo fittings on the left side of the bike.