Removing the boost return system (again)

[brookescourt 0]

Right,

I'm nearly ready to remove everything as soon as my blanking plate arrives. I would go for twin inlets but as I've fitted a Golf G60 intercooler I don't have the space.

I just wondered if anyone had any pics of their setups? I'm looking to see what you have done with your ISV pipe and the boost return pipe which comes from the throttle body mainly.

I don't seem to have a leaky ISV so I shouldn't need a Giro valve so I was thinking of fitting a small crankcase breather to the ISV pipe. Not too sure what to do with the boost return pipe though.

Thank in advance,

Rob

[Dubcharged 0]

Stick a filter on the ISV and hang the boost return pipe on your wall as a souvenir!

[VR6 0]

Could this not have just been kept in the other thread?

 

Just a thought - would've made it easier for future reference, as it was quite a good thread, content-wise

[mambomonkey 0]

I have just done this and lost the return pipe altogether. Easiest thing to do is to whack a k&n breather filter on the isv. Also, if you leave the wastegate totally exposed you get a mental dumping sound after 3500rpm :twisted: ....-Not everybody's cup of tea, - if not just leave the rubber hose which would connect the return pipe to the wastegate on with the metal gauze in it's end, - this quietens it down.

[brookescourt 0]

Thanks for the help and advice everyone has given me so far.

I removed everything at the weekend and am very pleased with it. I used K&N crankcase breathers in the cam cover and on the ISV pipe and I re used the rubber elbow with the metal gauze modded to fit into the elbow to keep dirt out but that blew off last night!

I seem to be getting a bit of oil coming out of the K&N on the cam cover (but it may be just the K&N oil as I think I used too much) Has anyone rigged a oil catch tank up? A local motorsport shop has got some for £30 and I'm thinking it could be modded to work but I havn't a clue where to mount it.

Cheers guys,

Rob.

92 G60.

[W3RKD 0]

yes use a catch tank on the breather otherwise you will end up with a horrible mess in your engine bay !! thats not k&n oil coming from the filter its a breather from the head remember

[Dubcharged 0]

Rob, use the standard breather filter and stick a plastic bottle with vents cut into it for now. I'll have a custom made catch can for the G60 coming out very very soon! You'll love the way it mounts! :D

[mambomonkey 0]

Like the sound of those catch tanks. How much they gonna be roughly?

Cheers

[brookescourt 0]

Bilal,

Will it still fit in my car bearing in mind I have fitted the intercooler set-up from a Golf G60?

Have you got any pics/prices etc?

[Toby 0]

Bilal,

 

Keep me posted on that catch can please. I've been trying to find a good (yet inexpesive) one...

 

Toby

[Dubcharged 0]

It will fit your car with that intercooler no probs Rob.

 

As for price well i cant say yet, still working out costs etc but i'm gonna keep it as low as possible you'll get what you pay for! It will look great (polished) and will work very well, well of course it will its designed by yours truly :lol: :lol:

 

Maybe i'll do a group discount when its ready!

[16VG60 1]

Ref the parts you are seeking. the blanking plates you may be able to source from my ex PDM partner Darren, i know he wishes to stay involved with specialist fabrication. Darren may also have further developed breather catch tanks for sale. Failing this, and in no way wanting to rain on Bilal's parade, i have used Stroeve tanks via Eurotek. Have a look at Bilal's product first however as the Stoeve items are a little pricey but pretty all the same!

[brookescourt 0]

Thanks John, I did get the blanking plate from Darren. I know have another question,

By removing the boost return pipes and blanking off the right hand of the charger, am I getting enough air into it? I ask as the air coming out of the wastegate does not seem that hot and there is a lot of it!

Any ideas guys?

Cheers (again)

Rob.

[Dubcharged 0]

When you go full throttle the bypass air shuts off since the butterfly for that side closes fully. So removing the bypass makes no difference to the amount of area through which the charger can draw air in.

 

Put another filter on the left side of the charger! just make sure you can route it away from heat.

[16VG60 1]

Personally i would choose to install another air intake to the boost return side of the charger. This would keep the internal preasure balanced within the charger, and allow for a much improved induction of air. I agree with Dubcharged that this additional air intake must not allow warm air to be draw in.

[mambomonkey 0]

To do this you need to move the rad considerably though don't you? - What the best way to do this, - is it a case of fabricating new brackets e.t.c?

[16VG60 1]

Mambo, in order to fit an airbox worth having here you do need to lower the rad location. I carried out this mod on my own conversion and later we did the same to Darren,s C. Although i might add we changed the setup on Darren's further to incorporate a different rad, as this suited his requirements better. This does make the process of creating another air inlet a little more long winded, but the best results never came easy. If you would like to discuss this further and what gains can be had drop me a pm.

[brookescourt 0]

John/Bilal,

I dont think I will be able to move the rad on mine as I have fitted a Golf G60 intercooler so I have already moved it back.

Do other people who have removed the boost return system get a lot of squeaks and whistles too?

At the moment I am seriously considering refitting it all at the weekend.

[Dubcharged 0]

One of the whistles may be coming from the larger outlet downstream of the bypass butterfly. The large hose which went into the black valve was attached here.

 

You could try putting a longer hose and blanking that off or just leave the hose open since its downstream of the bypass butterfly so you wont loose boost.

[16VG60 1]

The spurios noises are entertaining at first, and then in many owners experience become evermore tedious. A longer pipe from the throttle body boost return may ease the situation but will not make it go away. The only way to do something beneficial with this is to make it into another intake. I hear your prob with this but necessity is the mother of invention, in this case to remove the mother of noises :lol:

[g60rado 0]

After removing the boost tube and placing a breather filter on the crank case, what did you guys do with the conncetor that plugs into the boost return pipe?

 

I removed the isv and left that plug undone, but where is the idle screw that i need to adjust? I'm guessing its the one on the back of the throttle body that looks kind of hard to get to.

[G60 0]

just leave that plug hanging... just for a heater element and you dont need it.

 

youre right about the idle screw location. buy a spare if you're gonna fuck with it.. i blew mine off on saturday after adjusting it.. been whistling all weekend.. goin to pick up a new one after work. :roll:

[g60rado 0]

ok sounds good, i'll give it a whirl and see how it goes!

[mambomonkey 0]

Talking of funny noises, on mine i get a crazy high pitched whisteling on part throttle at low revs. If you put your foot right down in low revs for that gear ( say 4th) you sometimes get a crazy little tune as the whisteling rises. It then disapears after 3000rpm or so. As i say, i've dumped the boost return completely, blanked the charger (cheers Darren), got the wastegate dumping to atmos. with a kn breather on the end of the isv pipe. Any suggestions as to what this noise is, would be most enlightening!!!!!! :? :) :?

[W3RKD 0]

sound like you may have a small boost leak somwhere ??