Ron's non-intercooled guide is hence nominated for the read of the year. I have done all the recommended stuff however prior to fitting an intercooler on Sunday and blanking off the egr there was no noise from the turbo and now it whistles from about 1500 rpm to 3000. Elsewhere on the forums turbo whistling is said to be just a characteristic of a turbo spinning freely whereas others say it is indicative of impending doom so which is true?

I need to know if I have to put aside another Sunday afternoon to fit a new turbo.

Also should I now change my ID to 420Di ?

Don't worry about the whistle, my 825Di did it for 285 thousand miles, and was still fine when I sold it ;)
Jim

is there any other syptoms like smoking or anything, abit of whistleing noise is common, and is emphasised with a induction kit

No other symptoms and the standard airbox and paper filter are fitted, have decatted and upped the pump and the noise only started after fitting the intercooler and blanking off the egr, previously the egr was just unplugged.

Just check that all the plumbing is nice and tight for the new pipes and that you've not accidentally pulled the pipe off/loose from the air filter to tue turbo. If you do you'll hear it whistle a lot more than before.

Thanks E_T_V I checked the jubilee clips this morning and the one from the turbo to the outlet pipe had worked loose from when I had fitted it on Sunday, I've put a new clip on nice and tight and this has reduced the noise a bit.

No other symptoms and the standard airbox and paper filter are fitted, have decatted and upped the pump and the noise only started after fitting the intercooler and blanking off the egr, previously the egr was just unplugged.

There we have it mate.

De-cat.

A De-cat allows the turbo to spool up easily, thus making a nice whistle noise!

It does it on my Rover.

the turbo will whistle more, it now has a much longer path for the air t go so the sound will be amplified through all the new pipework, this is nothing to worry about

Whistle could just be the De-cat no dampening the sound of the turbo anymore.

De-cated 306 owners report this on D-turbo's

its great when your putting some throttle down in town, people look and go wtf its a derv! :lol: then Pwarrrrr what a stink :naughty:

Decat was not the cause of the whistle as I did this in the summer and the noise only started yesterday after fitting the intercooler. The whistle isn't really annoying, it'll just take some getting used to.

One pleasing thing is the half a tank I've used since Sunday has given me 250 miles, 30 more than before fitting the intercooler.

Whats the performance like with your intercooler fitted? was it hard to do or take hours?
Cheers Ray

It took pretty much all day on Sunday as the exhaust manifold was a sod to get off and I didn't want to disturb the turbo components or undo the exhaust from the manifold. It's a real pain and an odd design that the exhaust manifold fits over the intake manifold so you have to move it out of the way first. The throttle cable mounting next to the pump is in the way of the top intercooler hose where it goes into the intake plenum so had to be forced as well. Other than that the torx bolts that hold the frame that sits where the intercooler goes are really tricky to get at and I had to contend with a exhaust manifold bolt that had previously unknown to me snapped off in the head.

Worth the effort though as much freer revving now and more power and torque. Having fun at the moment tinkering with the pump and the boost compensator to ensure I can leave people behind at the lights without leaving them in a cloud of smoke.

It's gratifying to know I've done all these mods and it's cost me no more than a couple of weekends and about £100.