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Josh's Leon FR tdi. R32 interior fitted.

joshy514

Fleet Air Arm by ability.
Mar 2, 2012
1,836
4
Gloucester
www.seatcupra.net
It sounded like a jet just after the mufflerectomy though, no real difference. No it's being mapped out this weekend fingers crossed, but also the car is being treated to a custom 2.5" SS turbo back.... So I expect it to sound a little different. Because its partially the vibration on idle I think, It's so loud! The only difference between mine and a mates (engine end of car) is the dogbone mount, and mine hasn't got the sound proof thing on the bonnet, which is also going back on this weekend.
 

turboboy

Limp Mode Squad ™
Dec 9, 2003
2,007
3
39
hants
Is yours an uprated dog bone? I'm running a standard dog bone and its fine.

I had my mufflerectomy done with the egr in place and tick over was very quiet, just sounded like a petrol from the back end but after egr delete it made tick over much loader and wooshyer. Could you do a vid of yours on tickover ?
 

joshy514

Fleet Air Arm by ability.
Mar 2, 2012
1,836
4
Gloucester
www.seatcupra.net
Yeah it's a powerflex red one, got a new oem one in the boot to go back on, sorry should have explained. I will do a video but its at the garage at the moment, I've got a few videos of various stages ill try sort something out
 

turboboy

Limp Mode Squad ™
Dec 9, 2003
2,007
3
39
hants
Nice one thanks. Want to know if it sounds like mine on tickover. But your saying yours was the same per and post egr delete ?
 

joshy514

Fleet Air Arm by ability.
Mar 2, 2012
1,836
4
Gloucester
www.seatcupra.net
Been let down by this company AGAIN! Apparently they haven't been able to do the welding! That's the last time I go to them now. I'm going to have to save up for a milltek now then! When will the money end....
 

joshy514

Fleet Air Arm by ability.
Mar 2, 2012
1,836
4
Gloucester
www.seatcupra.net
Binned the brakes off, just going to buy LCR wheels and brembo's when I'm back.

Any way, where do I start?

Succesfully deprived the car of it's gearbox and turbo today.

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This picture I tried to capture the horrible slimy **** in all of my boost pipes. It was a mix between green and grey snot! I'm pretty sure that that revive turbo cleaner caused it.... It was in every pipe I took off today, and there is only one left on the car! So for you diesel boys, and any petrolheads brave enough, I wouldn't personally reccomend it.
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She is literally in bits!

Turbo is off tomorrow for a recon, then hopefully get it back Thursday afternoon to put the whole thing back together. Also tomorrow, I'm taking the gearbox down to the local VAG garage to ask if I can borrow that horrible torx/spline bit to empty and refill the gearbox, order some new gaskets, oil and an oil filter! It's not like I can crack on because the cars on a ramp, and the engine is being held up by a jack, by the ally sump lol. Needs a new one any way. Lovely thick black oil coming out of the hotside of the turbo! Definitely just on time for new bearings and seals haha.

Just a couple of pictures of mine vs standard Leon FR tdi.
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Just a comical one, I was on the M5 south on Sunday night driving back to work, and saw something in the middle lane, It was a dead badger.... I was doing 70 and thought.... **** lol. It hit underneath my car, had bits of badger flesh and fur from the subframe all the way back!!
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If anybody wants to come lick it to proove it's not ketchup or jam you're more than welcome!
 

joshy514

Fleet Air Arm by ability.
Mar 2, 2012
1,836
4
Gloucester
www.seatcupra.net
Did you kill it? If this badger wasn't dead when I ran it over, it 100% was after, the whole car jumped up! I had to stop and check my sump lol! I was expecting worse to be honest, like overcooked badger on the exhaust but none really on there. Smelt really bad though
 

joshy514

Fleet Air Arm by ability.
Mar 2, 2012
1,836
4
Gloucester
www.seatcupra.net
Update again, Gearbox is now in, starter and most ancillary pipes etc....clutch bled. Took the inlet off to give it a clean and it was a mess! took a good 2 hours to get it clean, but now its 99% better! Picked up the gearbox, so it's got fresh oil and Midland Turbo's gave me a ring, good news the turbo has just had seals and bearings, and a full clean. They said they VNT's were the problem, and that cartridge has no damage whatsoever. Happy days! Only £222 inc VAT, got picked up yesterday, and being delivered back to me tomorrow! 3 day turn around and a fully working turbo, inlet, exhaust, egr cooler, turbo oil drain gaskets, oil and filter change, new gearbox oil, and an OEM dual mass, pressure plate, CRB and clutch for under £800! £746 give or take, not including the amount of beer I owe lol. She should be at her best after this, as all the boost pipes are clean, the turbo and inlet mani are spotless, gearbox oil is fresh, and obviously the big job the dmf is new! Recent brakes, 256's to go on whenever the discs arrive and new suspension, and bushes! IF it all goes well that is, I rekon she'll be back together on saturday. Just some pics from the day.
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Back on her wheels after 2 1/2 days!
 

turboboy

Limp Mode Squad ™
Dec 9, 2003
2,007
3
39
hants
It was already dead but in the road, my under tray tore it up and scooped it up. Had to scoop its body out and jet wash all under my car, flies were flying under and around my car. Car was very low at the time
 

dgjdrummer

Part-timer
Nov 5, 2011
1,310
4
Wrexham, N. Wales
That inlet mani looks 10x better than mine currently does! How difficult is it to get out? Do you HAVE to remove the turbo to get to it? Think it owuld improve my car's mpg and performance quite a bit!

Kudos on the amount of work going on recently, how is it running with the reconned turbo and cleaned intercooler/inlet piping?
 

joshy514

Fleet Air Arm by ability.
Mar 2, 2012
1,836
4
Gloucester
www.seatcupra.net
That inlet mani looks 10x better than mine currently does! How difficult is it to get out? Do you HAVE to remove the turbo to get to it? Think it owuld improve my car's mpg and performance quite a bit!

Kudos on the amount of work going on recently, how is it running with the reconned turbo and cleaned intercooler/inlet piping?

It would be alot easier with the turbo off! just access would be so much easier.

It's running like a piece of **** if I'm honest, the only thing is the boost is smoother on the gauge! First problem was the rattle plate between the box and engine, was hitting on the flywheel! **** myself when I first turned her over! This is all fixed now, but I have bigger problems, the turbo is chucking out a serious amount of oil out of the dp! I don't know what it could be, it was slightly overfull after the oil change, because I was lazy and did 4.5l off the bottle instead of using the dipstick, so I drained some oil and unplugged the crankcase breather, but no luck! Also, took the bumper off when I didn't really need to, to clean the cooler, but this has only minimal oil in it, so I'm not worried about that, as there was no oil in the pancake pipe or the bright red one, so that's not the problem. (Turbo didn't actually go boom, so I didn't bother cleaning the intercooler) Checked the oil drain pipe and its all free, and oil flowed out of it when I took it off, so it's working. So, the only other things it could be, is the oil feed pipe or the seals have gone already! I've ordered darkside's braided one just incase the original pipe had a restrictor or something I blew out with HP air. I will give Midland Turbo's a ring tomorrow, I think it will have to be remanufactured again to be honest! But I did everything they said to do, made sure all the pipes were clear, clean boost pipes and i/c (for a broken turbo) put oil in the turbo, (bit of a bodge that I didn't turn the engine over I know but they won't) All new gaskets, OEM ones, not the shite they supply. New oil and filter.

This week or so has seriously made me skint, Mr. Lloyds loves me I tell you that! Had to order new driveshafts too because I can't get the CV's off the old ones.... and now maybe another £250 on the turbo being reconned again!! :( I'm just going to try and say I did everything they say, so it must have been their balancing skills or something! Anyone free to take a turbo off with me tomorrow pop down to Culdrose!

Ordered a steering rack polybush too, mines a little tired, I would get an ARB considering the subframe is out, but don't have the funds :( Ahh well subframe is a piece of piss on a ramp.... Cheers for looking, feel sorry for me!
 
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turboboy

Limp Mode Squad ™
Dec 9, 2003
2,007
3
39
hants
If you have just paid for the turbo to be done why would you pay again... Take it back and kick off. Over filling it wouldnt of wrecked the turbo..
 

joshy514

Fleet Air Arm by ability.
Mar 2, 2012
1,836
4
Gloucester
www.seatcupra.net
No, I rang them today and had a massive go, so It's going back tomorrow for a 'good will' gesture I believe. I'm not paying!! It came off in about 50 minutes, getting too good at this lol!
 

brett1223

Active Member
Dec 15, 2012
77
0
Durham
Ordered some flo-flex bushes and came today. Look like good quality and il get them fitted asap! Cheers for the info Josh!
 

joshy514

Fleet Air Arm by ability.
Mar 2, 2012
1,836
4
Gloucester
www.seatcupra.net
Ordered some flo-flex bushes and came today. Look like good quality and il get them fitted asap! Cheers for the info Josh!

Is this for the top mounts?

Well, turbo is off again, it was meant to be picked up today, I rang midlands at 1700 and they tried telling me it had been collected, when it's still in the boot of the black Leon! So it will be picked up tomorrow now, just ANOTHER day the car won't be running! I really hope it's worth it, steering rack powerflex arrived today. Bumper is back on her too. I read on someones thread a while ago that they've struggled putting the bumper on because of the sliders, it's simple.... just put the sliders on the bumper and then fit to the car lol. Not much I cn do tomorrow withoug the turbo....
 

joshy514

Fleet Air Arm by ability.
Mar 2, 2012
1,836
4
Gloucester
www.seatcupra.net
This is why the turbo didn't work, oil in the hot side!
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She's in bits! Can't wait to drive her again!
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Didn't have anything to do, so I FINALLY fitted these! Need to bleed them and grind abit of a 16mm spanner down so I can fully tighten the sliders though. Also, need to do rear bearings and LCR dust gaurds, as I just cut and bent them instead of fully removing.
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One more thing,
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joshy514

Fleet Air Arm by ability.
Mar 2, 2012
1,836
4
Gloucester
www.seatcupra.net
Today I'm in the same position as last Friday. Turbo is being delivered at 1600ish, so will be on today, don't know how late I'm going to work on her, last Friday was 0200!

Got a new oil feed pipe delivered from darkside, and spoke them on the phone about my problems. they've said if it's still forcing oil past the seals, then I need to get 4 of the 6 holes on the banjo bolts tig welded, to restrict the flow etc. Apparently running it for a couple of days with oil won't affect the turbo in the long run, just blue smoke and will have to keep my eye on oil level. Had all new seals and bearings and the chemical clean yet again.... and this time I've got the new oil feed which will be a lot easier to fit, as it can move freely rather than the OEM one being a rigid pipeline. Still haven't tested the clutch is working properly yet either!
 
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