Issues: Interface between the BPV and intercooler
 

Something isn't right between my BPV housing and intercooler. The IC bottoms out in the housing, but there's a healthy gap. Compounding this, the o-ring feels like it isn't creating a tight seal. What's the deal?

I'm going to smoke test the system tomorrow and expect this to be the area that is puking boost. Pics:

http://forums.pelicanparts.com/uploa...1445130275.jpg
http://forums.pelicanparts.com/uploa...1445130291.jpg

Kenik, for one thing, you are missing the second o'ring - one goes on the intercooler spout and into the secondary intake manifold's opening (not like that, all you pervs!), and another goes in the gap you see in pictures and gets squished between intercooler and manifold..

I'll take a picture late tonight when I get back home, if that will help.

This?

930-110-379-00-M136
http://forums.pelicanparts.com/uploa...1445132511.jpg

No, regular o'ring - same as the one that is on the intercooler spout.

That pictured is a vibration damper that goes between the compressor up pipe and the intercooler.

I guess a pic will help. The red o-ring?

Here's mine ...

[IMG]http://i50.photobucket.com/albums/f3...pssjwxo2fg.jpg[/IMG]

^^^ There's also an inner seal about an inch down.

Inner seal is there. Thanks for the pic.

Kenik, maybe you've already located these, butt if not, here is the correct o'ring.

Pelican Parts - European Automotive Parts and Accessories - Porsche • BMW • Mercedes • Volkswagen • Audi • Saab • Volvo • MINI


Page 65, item #2 of the PET - note that 3 are required even for stock intercoolers (1 on the entrance spout and 2 on the exit). Same size as as your 1979, btw - never changed.

http://www.porsche.com/all/media/pdf/originalparts/usa/911_USA_87_89_KATALOG.pdf

I have similar alignment problems when the up-pipe from the turbo becomes rotated slightly from it's correct position. On mine, repositioning the up-pipe brings everything back in alignment. My car is stock but I think that would still apply. Worth a look regardless.

Here is how my B&B mounts.

https://farm4.staticflickr.com/3760/...83969d70_b.jpgIMG_6158 by Shannon, on Flickr

https://farm8.staticflickr.com/7277/...018585c7_b.jpgIMG_6157 by Shannon, on Flickr

Surely, the inner seal is what's critical since it sits in a machined groove with close tolerances to seal when the IC is mounted. I've often wondered about the outer seal's effectiveness, but it sure can't hurt.

Part of its purpose, buttofcourse, is to help position the intercooler correctly, Mark.

The PET is wrong? It shows this as a seal between the IC and BPV. Page 65 from the link above.

^^^

Kenik, on page 65, what you have pictured above is item #3 - seal between intercooler and up pipe (same part number you typed, too). It doesn't do any sealing, however - just a vibration damper and to prevent metal chaffing between the intercooler and up pipe.

I will teach you, bro!!! :D

PS - the BPV spout is not pictured in the PET drawing on page 65 (only the up pipe spout), but note that is says quantity of 3 for item #2 - that's because they are the same sized o'rings on the intercooler and 3 are needed.

Derp on me

Careful, Ronnie's likely to interpret "derp" as only he can and volunteer to do it.

^^^

Im'ma "derp" you, Norm - two times!

Who needs OEM o-rings when you have mil spec in any size under the sun?

McMaster-Carr

I am considering purchasing some oversized rings of various materials to see if I can't get a better than OEM seal at the neck interface point. Smoke test first, though.

Do the double 0 rings also apply to the 964 i/c?

Kenikh -- I also see an aluminum spacer between your factory boost recirc housing and the intercooler bushing mount -- that should not be there, just a 25mm fender washer if anything (one on each side of rubber mount, compressing it).

gumba -- no, 965 IC does not use this, just a single o-ring on the t-body.

Good eye! From the size (length) of that spacer, if it were removed it almost looks like the IC would sit too low to where that outer o'ring - if present - would squish/distort out shape. I wonder if he's dealing with a stock IC, or some aftermarket that required that spacer due to how it was constructed.

Spacer is in place to accommodate the aftermarket IC, apparently. Gonna know more shortly. It is all coming apart, to align and seal.

No need for that spacer that C.C. spotted with a Garretson 1/2 bay like you have (I have the same intercooler). Maybe the rear of the intercooler (towards the rear of the car - different than Paul's rear) is riding high due to alignment issues with the compressor up pipe, and the spacer was used to make it sit flat? If so, you might need to clock the compressor housing in order to change the up pipe angle and position slightly., and bring the rear of the intercooler down. Pretty easy to do - don't know if you've clocked a turbo before, though.

I had to clock my K27 HyFlow twice - at first install and then re-install after the new unit required a rebuild after 10 mins of runtime.

Clocking a turbo? Been there, done that. I've owned a Subaru, after all. I was thinking alignment, as well. Turns out NONE of the seals are in, up pipe or BPV. I'll be real meticulous when they do go in. Shocked I've measured any boost...but damn, even given the discrepancies, it is the best car I've ever owned. 4th 911, none compare. 930 is as good as it gets.

Sounds good!

Again, sorry if you are already aware of this, but you'll want to lube the seals very thoroughly before insertion - hardy har har! I've found that silicone grease, like is available in the plumbing sections of hardware stores, really works the best. Spray silicone lube doesn't work with a damn as it dries way too quickly (like wemmins Norm gets with).

I have a silicon Wurth lubricant I can bring in to the office today if you want.

Is this code for errrrr, ummmm, something else ?!?!?! :eek: