New WAIC replaces laminova

[Gizmoman]

I'm replacing my DIY laminova WAIC with one from Frozen Boost.



I hate doing this but the rebuild seems to have plenty of fuel to get the van up a grade at 65 mph, but I don't think it's getting enough air to keep the EGT's in a decent range. I am hoping this new WAIC which only has a .1 pressure drop will do the trick.

I was able to get all six bolts out of the intake and only needed to remove the exhaust pipe. I really didn't want to remove the turbo and manifold (not saying I won't before it's over).

One thing that really concerns me is the amount of oil in the intake. I have routed my blow-by to a catch-can of sorts and do not introduce any oil into the intake (intentionally).



Here are the two cores from the intake



Can't tell from the image but they are both fairly coated in oil which would partially explain why they weren't cooling off the air much. I need to find a solution before I install the new IC.


Can anyone tell me where this oil is coming from? I'm guessing it's the turbo and if so, I have no idea how to stop it. It's just been rebuilt with a 360 thrust bearing and the full circle ring. All four ports have oil in them. #1 appears to be the most oil but I believe that's simply due to the tilt of the engine.

Any comments appreciated.

[bbob203]

AFAIK there will always be a little oil in the intake/ intercooler.

[Gizmoman]

AFAIK there will always be a little oil in the intake/ intercooler.

And that would be from the turbo?

[Gizmoman]

I suppose the "oil in turbo intake" has been a very common thread. After doing a bit of research, I suppose it's probably OK. For one thing, I just recently overfilled the crankcase and this may explain the oil.
I'm going to just proceed with my IC install and see how things go.

[CrazyAndy]

Sorry to hear the experimental intake was a bust; would've been nice if it worked, then we could all have a nice compact option for ICs.  So you got the 300HP hit?  Looks good; mounting going to be an issue?

[Gizmoman]

Sorry to hear the experimental intake was a bust; would've been nice if it worked, then we could all have a nice compact option for ICs.  So you got the 300HP hit?  Looks good; mounting going to be an issue?

I did do a new design in Solid Works using four cores and I think I could make it fit into the space, but I'm done messing with them. The Frozen Boost IC is is their #9 model,  they say good for 350 HP with 450 CFM air flow. I know diesels flow more air than gassers though so I don't know how it will stack up. I can see the huge (to me) core inside and it should be able to handle some oil getting on the fins. The laminova cores have such small gaps between the fins, I think the oil that is apparently "always" in the turbo air, could severely restrict air flow. Not to mention insulating them from soaking up much of the heat that's in it.

It's tough going back to square one but it's that or quit, and I can't do that. I suppose that's the price you pay when you fiddle with stuff, sometimes  it doesn't work.

As far as mounting it, I believe I can mount it into the cubby at the bottom of the left rear air intake on the vanagon, right behind the DS tail light. We'll see. If I can, the piping should be quite short.

I am also hoping to re-do the manifold and use some runners as theman has suggested. Obviously the manifold I have is not going to cut it after I tweaked it for the cores.  I really wish I had a better turbo now that I'm in this deep. My goal is to be able to run up the long I-15 grade East out of Riverside (East LA), fully loaded in the summer, at at least 60 MPH. If I can do that, I'll be a happy camper.

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[Toby]

Oil out of the compressor side is never a good thing. Have you looked at the cold side to see if it is actually coming from under the impeller? I have never liked the idea that only good intentions and maybe gravity keep the oil out of the air stream in most diesel turbos. The Garrett in my 7.3 Banks setup has a compressor seal. It sounds like a good idea for everything. Runaways are not my idea of a good time.

[Gizmoman]

Oil out of the compressor side is never a good thing. Have you looked at the cold side to see if it is actually coming from under the impeller? I have never liked the idea that only good intentions and maybe gravity keep the oil out of the air stream in most diesel turbos. The Garrett in my 7.3 Banks setup has a compressor seal. It sounds like a good idea for everything. Runaways are not my idea of a good time.

I'm actually glad to hear you say that. I don't like the thought of a runaway either or spewing oil on my IC (maybe that's why I'm up at 1:30 as well). I don't believe the k-14 has a seal on the compressor side. There is one on the hot side and I have no oil in the exhaust. Is there a way to install a seal? Is there a comparable turbo that is built better but costs less than 1300 bucks? I'd love a VNT-17 but man they are spendy.
The oil I am seeing now could be from my recent over-fill. I put a lot of effort into insuring the drain is at 6:00 and that there are absolutely no restrictions. It leaked oil on the compressor side when I bought the van but I figured it was because it wasn't clocked at 6:00.

I have read though that if air does get by, it makes the oil get foamy, then it starts backing up in the drain line. I believe the stock setting for the K-14 is 10 PSI and I have this cranked up to 15 and it's still not enough air for the fuel I'm dumping into it. Maybe at 10 it would be OK but that's not enough air for my application.

[RabbitJockey]

what all is done to your engine?  its possible that the k14 simply isn't enough turbo for your setup, which could be why the compressor oil seal is leaking... i don't think that amount of oil is normal for an engine that doesn't have the crank venting into the intake.

[theman53]

I would get you intake on and break it in a little more before going too crazy. If I were you and you want another turbo, I would go with that cheaper HE211w from the Alcaid dude. 600.00 and some fab work and you would have a much better turbo than the K14 and I would say "better" than the 15 or 17 vnt. I haven't run it but the HE221w spools almost as fast as the 15 in the alh car I have with a stage 2 tune. Almost unnoticeable difference in spool up time, and if the 211 is a fuzz smaller I would bet that it spools just as quick, but has a lot more psi to give than the vnt.

[theman53]

also, there is plenty of intake left to build onto if you cut right at your weld or a little below. I basically had the turn up and that was it. I didn't have as much vertical as what you have after the 90 bend.

[bbob203]

Thread on using a gt2052 on an ahu.

http://forums.tdiclub.com/showthread.php?t=360678

He sells the adapter plates for $90 shipped.
https://www.facebook.com/photo.php?fbid=512950112059126&set=a.512950105392460.114764.188243454529795&type=1&theater

http://www.ebay.com/itm/Turbocharger-Garrett-Perkins-2645A305-GT2052-727264-5004-C4-236-engine-/201031423420

[theman53]

another good option, but I think the holset would be even better and cheaper yet. The fab work in the van would be easier than a mk2 as well.

[libbydiesel]

another good option, but I think the holset would be even better and cheaper yet. The fab work in the van would be easier than a mk2 as well.

That may not be the case.  The vanagon has a mounting bracket on the back of the turbo that mounts to the same four locations as the mk2 bracket but is MUCH larger.