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I'm still shocked by your luck with finding that Jordan, most of us would have found the new charger the day the old one returned from being refurb'd!!... :)
 

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Discussion Starter · #1,322 ·
I'm still shocked by your luck with finding that Jordan, most of us would have found the new charger the day the old one returned from being refurb'd!!... :)
I have a penchant for locating things 😎 but yes, luck played a part indeed! Glad I phoned to get a diagnosis first
 

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Discussion Starter · #1,323 ·
The charger will be getting replaced next weekend, I have managed to get access to a proper walnut blaster through a friend of a friend... so should be able to get the ports nice and thoroughly cleaned rather than what we did last time.

Repeating tasks has its advantages
 

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Discussion Starter · #1,324 ·
So even with the charger being new, I don't know how old it is and how long the oil has sat there, I have some new oil so.... removed the 3/16" plug and drained the oil:



Filled the oil until it dripped out:



Put the new fill/drain plug in along with the new o ring it comes with:



Once the other charger is off, will likely swap the dowels to resolve the damaged ones on this. Hopefully come Saturday afternoon the charger will be whisper quiet on idle and the car will be a little louder...
 

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The old oil looked OK? Did it smell OK?
 

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Discussion Starter · #1,326 ·
The old oil looked OK? Did it smell OK?
Looked and smelled fine, but took about 5 minutes to do and once I Emptied it out no point putting the old stuff back in when I have brand new, well I didn't think so anyway...
 

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Totally understand.
 

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Is there only oil at one end on these superchargers? When I serviced the supercharged Mini that unit has an oil filled gearbox at both ends.
 

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Discussion Starter · #1,332 ·
Another split update, really needs back tracking to the old version without the limitation 🙄

Part 1

Another fairly sizeable update....

Charger came off again, started getting it out:



Can see the Mahle air con rad with intake removed:



Continued with the removal:





Until it was only lifting it out to be done:



Lifted out:



Both chargers, removed the snout as easy to swap them rather than faffing around with the pulley itself:



When separating there's residual sealant:



Easily solved:





Light smear of rtv when reassembling:



Then it was onto the issue of the new charger, which you can see in the above picture, damaged dowels... took a long time to sort but was obviously a necessity:

Heated them:



Twisted them out:



The damaged ones were Drilled out and pulled, they fit back in nicely

New one all ready to go, whilst old one was stripped:



A comparison of rotor wear, old:





New:

 

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Discussion Starter · #1,333 ·
Part 2

The PCV system is readily accessible with the charger off, so thought may as well change the serviceable part whilst in there:



Pulled them out:









Testing the old one they seemed fine:

XFR PCV Diaphragm

New one ready to go:



The o rings for the metal connector for the water pipe were a little worse for wear:





Old vs new:



New fitted:





Replaced the throttle body gasket:



Replaced the Valley pipe, and then obviously refitting was the next order, and, the start up and moment of truth:


All running, no issues and the clunking has gone! Success.

Closed the bonnet to end the saga:



Now onto the next project, exhaust....

New exhaust:



Old removed and shows the new pipes matching the old:



Exhaust fitted:






And here it is on a cold start up:


Happy with the outcome all round
 

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Top work Jordan!

And yet again, nice documentation!.. :cool:
 
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Discussion Starter · #1,335 ·
Air con system was serviced last night, 3 degrees at the vent, lovely and crisp!
 

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Discussion Starter · #1,336 ·
I got bored so decided to play with the old supercharger...

Removed the end casing that contains the oil:



Exposes the timing gears for the rotor pack:



Looking at the inside of the end casing there were what appeared to be impact marks:



Down the opposite end is the section of the rod that connects to the snout via the coupler:



Here are a couple of videos that show the play the rotor pack has along the shaft, I presumed to the bearings in the timing pack:



The rotor pack comes out as a whole unit, prising out from the end of the timing gears:



The connector on the the for the coupler needs to be removed before the rotor pack will leave, there are three threaded holes in it, so got some relatively long bolts of the correct thread:



Started tightening them gradually and sequentially:



Then it simply falls off:



Leaving the rod through the rotor pack free:



Simply pull the rotor pack to remove it, leaving an empty (and in this case slightly rusted) casing:



Rotor pack:



Now, a video of the play in the pack, admittedly it has lost the stability provided by the rod going through bearings in the casing, but still worrying:


The case bearings, clear that the bearing that goes through to the coupler has started to fail also:



2 tiny bearings for the rod of the actuated flap on the charger:





The other side of the bearing that looks to be failing:



Safe to say it was not in good condition! If the timing of the rotor pack was not renowned as so difficult I may have attempted a rebuild... but no point as the rotor pack would have to go away for specialist coating and assembly and I doubt I'd see the money return

Still an interesting exercise
 

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Nicely done and documented Jordan, thanks for the share, interesting to see one pulled apart. (y)
 

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Discussion Starter · #1,339 ·
Car was running without issue until recently when it started lurching again, checked the codes and pointed back to MAF issues.

It was simply a popped pipe from the right hand side intake...

The sump leak got rectified today, here is the sump:



Changed the plug whilst at it:



Sump removed:



Relatively clean mating face and internals:



Pickup had a few small foreign bodies:



Cleaned the sump out:



Plastic razor to remove the sealant:



Cleaned the mating face (the little pieces of detritus were removed from the sump pan):



Cleaned the bolts:



Cleaned the mating face:



And the pickup:



Genuine sealant applied:



Torque wrench set:



Oil filter removed:



Air filters removed:



Cabin filter removed:



Got a warning come up after refit:




Read the code:



Checked the connection and clicked it home...

Got the reading and added appropriately:

 

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Welcome back Jordan. I assume you have been really busy at work recently?

Good work on the sump - tiny, isn't it? Just a low point for the oil pick-up I guess.
 
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