Justanotherhumanoid's 2006 S60 2.5T AWD Build Log Topic is solved

[abscate]

I missed this earlier

The engine back side banjo bolt is for coolant. That has to have flow, and no orfice

The intake manifold banjo is fir vacuum and has an orfice.

Don't mix them up.

I think I got this wrong. They show as identical part numbers in VIDA. It is correct that one flows vacuum and the other coolant but that doesn’t mean they can’t be the same.

There have been some updates to the vacuum banjo including a more robust pin that doesn’t fall out and ruin your engine, though.

[justanotherhumanoid]

Yeah, VIDA is confusing as the bolts do have the same part number even though they are decidedly different, so I simply matched the types as I removed them and opted to re-use one as it's not torque-to-yield or anything like that. I just replaced the crush washers. The block-side bolt in the IPD kit seemed to have a smaller hole for coolant and used a larger bolt head, and since it is damn near impossible to put that thing in even with the smaller 17mm bolt head, I chose to re-use the old one on the block-side and the new IPD one at the intake. Here's the excerpt from earlier about how I sorted it out:

Block side:
Original, block-side banjo bolt: 17mm bolt head, large bore-hole through the threaded part.
New, IPD block-side banjo bolt: 19mm bolt head, very small (1-2mm) hole through the threaded part. (Why is the hole smaller? I don't know.)
Intake banjo bolt:
Original: 17mm check-valve style banjo bolt.
New: the one in the ipd kit was the same as the one I took out. (Apparently not, though, I guess the new one is a better design?)

I'm glad I swapped out the vacuum side bolt as I didn't know there was a new/better pin design, so that works out. I'm still not sure why the replacement banjo bolt for the block that IPD provided had a smaller passage in it for coolant, or why the larger head. While I'm curious, I'm not particularly concerned about it, as it's likely a tweak of some kind rather than a critical component update.

[justanotherhumanoid]

Alright, it's been a while, but here's an update. I'm at a Stage 3, or thereabouts, since a 16T isn't a huge upgrade on these cars (but it does feel good). Here's a review/summary of where I'm at:

1. Stage 0+/preventive and regular maintenance items:

• PCV

• timing belt

• water pump

• replaced vacuum lines with color-coded silicone lines

• cleaned throttle body, installed phenolic intake manifold and throttle body spacers

• brake vacuum switch replaced

• vacuum pump replaced

• oil and filter change x2

• trans fluid flush using Gibbons method

• replaced OEM with silicone hoses throughout (everything except coolant expansion tank hose)

• new control arms

• replaced dented subframe

• new engine mounts

• thermostat

• engine and cabin air filters

• fuel filter

• alignment

• angle gear collar sleeve replaced (AWD restored!)

• painted front lower bumper cover

• replaced glovebox trim piece

• replaced driver's side window control

• replaced outer tie rod ends

• replaced leak detection pump

2. Did some upgrades:

• rebuilt and installed a junkyard 16T (used a kit from Gpop shop in San Diego, $99, comes with an upgraded piston ring)

• Hilton Stage 3 tune (still need to finalize this via logging but so far a great experience with Rob)

• 3" oval exhaust with Borla XR-1 muffler (kept stock downpipe and cat since the 2.5T downpipe measures the same as an "R" downpipe, which is good enough for me)

• Snabb intake-to-turbo pipe (apparently all you need as the stock airbox is actually pretty good)

• Snabb intercooler-to-throttle-body pipe (another bottleneck when stock)

• do88 drop-in intercooler (chose this because they actually provide performance data for their product(s)

• do88 all-aluminum radiator (chose this because the plastic-sided ones tend to crack, as my original radiator did)

• installed XC90 transmission cooler

• "R" brake upgrade, also stainless lines

• 17x8" Team Dynamics Pro Race 1.2 wheels

• Michelin Pilot Sport 3+ A/S 245/45ZR17 tires

• IPD front and rear swaybars

3. Currently in work:

• Need to either replace the prop shaft entirely or just the front coupler. I believe I damaged the front coupler when I was replacing the angle gear collar, since I now have a vibration at ~30mph. This will be done asap.

• Contemplating shock/strut replacement options.

• Need to clean up aux transmission cooler lines/fitment.

Some pics of progress so far:

[justanotherhumanoid]

...and some bonus pics....

New collar sleeve:

Still had good teeth on the trans output (thankfully):

Moving components over from old to new turbo:

Old turbo with hardware undergoing PB blaster soak before removal:

New and old collar sleeves:

Angle Gear Collar Sleeve Extractor setup (5-ton puller, 30mm socket, ziptie):

I cut notches in the collar sleeve per others' suggestions, worked like a charm:

Can't see it but the CBV also got upgraded here with the IPD kit. For the turbo rebuild, used a kit from Gpop shop. Lots of smoke when I started up the first time but I think most of it was excess fluids, oil residue from the turbo swap, etc. burning off as it did not persist. I used a moderate amount of Lucas Oil assembly lube wherever it made sense to as I reassembled the thing. Also, I cleaned off the housings (didn't put it back in looking like this):