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Faced with a clearly dead BCV.
Odd irreconcilable Boost issues.
But the Ohms on the BCV coils was on spec at 3 ohms
Stupid thing was only 2 years old and Bought New at foolish price.
I had not gotten my $$ worth out of it... yet :-)
With valve in hand I used a wee Zona (exacto type) saw and slowly carefully cut along it's glue join line. Once I thought I had sawn thru (deep enough 2~mm) the glue I Used a Spatula and popped/wedged the thing into it's 2 basic case parts: Barrel and bottom cover.
Inside there is a shiny metal cyl (coils / valve unit)there are 3 lugs where the Coil wires solder on. Mark/identify those wires and their relative solder points. Unsolder. Then remove the Metal unit It should fall our easily unless a wee bit of glue blob(s) impedes this.
The 2 coil tubes are pressed into a central ring containing the valve disc. These must be separated, I used a vise and a screw driver blade as a lever against the central ring.. (not the inner slot as that may damage it) carefully .. it does pry apart reasonably easily. Be Careful of the external wires and their connections to each other! Don't want to loose track of which connects to which :-) On this one the disc was shattered into several pieces. From research, the 'usual' failure mode.
I fabb'd a fresh exact copy disc from a single edged safety blade (window scraping type) Same thickness, similar hardened steel. Inserted it into the valve cavity. Using the Vise, pressed the removed coil back in.. there is a stop, so just squeeze (gently) until it bottoms.
Fitted New sealing O rings at either end of the metal assembly. Applied JB Weld in enough quantity to ensure a hermetic seal. Then Squeezed it together in the vise for several hours, allowing a thorough Epoxy cure.
Subsequently reinstalled : BCV now buzzes nicely and most entertainingly Boost is Back ! to end of Red and holding reasonably steadily till 5k rpm (ran out of road) possibly further?.
Emboldened: I 'repaired' my 'spare' BCV which annoyingly also refused to work.. Same routine as above. But on this one the wee disc had become glued to one of the coils. NO idea as to how or why. Carb cleaner had not budged it even after overnight soak.
Once apart, I cleaned polished the mating valve/coil/disc faces and now It too works 'as new'
Was about to order a T7 bcv and mod my ECU and software to use it.
Likely still will.. But at least there is no longer a dire need to do so.
As digression I found info re 'rebuilding' ABS sensors.
Again info from the Balkans, where motivation/skills seem more accessible than Pricey parts. This apparently Can and Has been done repeatably as well.
We may not be so beholden to Parts Supply(ers) as previously assumed.
posted by 207.6.23...
, Sat, 21 Jul 2012 15:11:31
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