Installed the stage 0 kit - works great so far. This noise was present the first time we started the car once it was installed, so before going anywhere.

I'm worried the turbo blades are getting beat up on the inside of the housing... any thoughts? It's getting oil... the noise is coming from the new turbo assembly SOMEWHERE. Seems like most likely the turbo housing. Can anybody who knows better ID this noise? ZPI offices are not open yet but I will show them this in the AM.

http://www.pixelogics.com/tmp/tC/noise.mov

 

Did you pull the intake pipe off and check for shaft play? Sounds like that turbo has a problem.

 

If the shaft has any more then 1mm side to side play, or any "in/out" play, that turbo is fubar'd.

Also it sounds like the blade is hitting the compressor housing, you should be able to see the marks when you check for play.

 

After further diagnostic it sounds like there is something rattling around in the wastegate. I'll check there too but hopefully that turbo isn't messed up. It still works so at least i could get a new one sent before sending the old one if that's the problem.

 

Open the wastegate up and check the spring, its fairly easy to do.

 

Yea, I will once it cools down. Probably early in the morning before I go to work.

 

I had the exact same problem. The internal waste gate flapper was not welded to the turbo housing. The flapper can spin freely and if the internal waste gate was not completely shut when the outside was welded then it can move and hit the turbo housing. This sound worried me and kept me from going WOT for a couple of days actually. Once I had 2 tack welds put on, the sound completely disappeared.

 

I think you're right on this. Because the housings are bathed in oil before they're boxed and sent to us, sometimes the welds we put on there don't stick.

There are two solutions to this problem. Take it somewhere local and have them tack it. It would be best to tack it internally as well as externally. Which means at the least removing the downpipe if they want to do it on the car, or removing the whole turbo and taking it somewhere.

2nd option is to send it to us, and we'll tack it for free, obviously, but it'll put you down a couple days while Brown (UPS) does what they do for you..